CLEANING OF EQUIPMENT FOR OXYGEN SERVICE - AIGA
CLEANING OF EQUIPMENT FOR OXYGEN SERVICE - AIGA
CLEANING OF EQUIPMENT FOR OXYGEN SERVICE - AIGA
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<strong>CLEANING</strong> <strong>OF</strong> <strong>EQUIPMENT</strong><br />
<strong>FOR</strong> <strong>OXYGEN</strong> <strong>SERVICE</strong><br />
<strong>AIGA</strong> 012/04<br />
Asia Industrial Gases Association<br />
298 Tiong Bahru Road, #20-01 Central Plaza, Singapore 168730<br />
Tel : +65 62760160 Fax : +65 62749379<br />
Internet : http://www.asiaiga.org
KEYWORDS<br />
• <strong>CLEANING</strong><br />
• COMPRESSOR<br />
• ENVIRONMENT<br />
• MEDICAL<br />
• <strong>OXYGEN</strong><br />
• PIPING SYSTEM<br />
• PREVENTION<br />
<strong>AIGA</strong> 012/04<br />
<strong>CLEANING</strong> <strong>OF</strong> <strong>EQUIPMENT</strong><br />
<strong>FOR</strong> <strong>OXYGEN</strong> <strong>SERVICE</strong><br />
Disclaimer<br />
All publications of <strong>AIGA</strong> or bearing <strong>AIGA</strong>’s name contain information, including Codes of Practice, safety procedures and other<br />
technical information that were obtained from sources believed by <strong>AIGA</strong> to be reliable and/ or based on technical information and<br />
experience currently available from members of <strong>AIGA</strong> and others at the date of the publication. As such, we do not make any<br />
representation or warranty nor accept any liability as to the accuracy, completeness or correctness of the information contained in<br />
these publications.<br />
While <strong>AIGA</strong> recommends that its members refer to or use its publications, such reference to or use thereof by its members or third<br />
parties is purely voluntary and not binding.<br />
<strong>AIGA</strong> or its members make no guarantee of the results and assume no liability or responsibility in connection with the reference to<br />
or use of information or suggestions contained in <strong>AIGA</strong>’s publications.<br />
<strong>AIGA</strong> has no control whatsoever as regards, performance or non performance, misinterpretation, proper or improper use of any<br />
information or suggestions contained in <strong>AIGA</strong>’s publications by any person or entity (including <strong>AIGA</strong> members) and <strong>AIGA</strong> expressly<br />
disclaims any liability in connection thereto.<br />
<strong>AIGA</strong>’s publications are subject to periodic review and users are cautioned to obtain the latest edition.<br />
© <strong>AIGA</strong> 2004 - <strong>AIGA</strong> grants permission to reproduce this publication provided the Association is acknowledged as the source<br />
ASIA INDUSTRIAL GASES ASSOCIATION<br />
298 Tiong Bahru Road #20-01 Central Plaza Singapore 168730<br />
Tel: +65 62760160 Fax: +65 62749379<br />
Internet: http://www.asiaiga.org
Acknowledgement<br />
<strong>AIGA</strong> 012/04<br />
This document is adopted from the European Industrial Gases Association document IGC 33/97/E<br />
‘Cleaning of equipment for oxygen service’ and acknowledgement and thanks are hereby given to EIGA<br />
for permission granted for the use of their document
<strong>AIGA</strong> 012/04<br />
Table of Contents<br />
1 Introduction ......................................................................................................................................1<br />
2 Scope and purpose..........................................................................................................................1<br />
3 International Agreements/Regulations.............................................................................................1<br />
3.1.1 Ozone Depleting Substances............................................................................................1<br />
3.1.2 Volatile Organic Compounds.............................................................................................2<br />
4 Cleaning methods ............................................................................................................................2<br />
4.1 Procedure and Agent Qualification...........................................................................................2<br />
4.1.1 General..............................................................................................................................2<br />
4.1.2 Selection Criteria ...............................................................................................................3<br />
4.1.3 Additional Technical Criteria..............................................................................................3<br />
4.1.4 Health, Safety and Environmental Aspects.......................................................................4<br />
4.1.5 Costs .................................................................................................................................5<br />
4.2 Typical Methods........................................................................................................................5<br />
4.2.1 Mechanical Cleaning .........................................................................................................5<br />
4.2.2 Chemical Cleaning ............................................................................................................6<br />
4.2.3 Solvent Cleaning ...............................................................................................................8<br />
4.2.4 Detergent Cleaning .........................................................................................................11<br />
4.2.5 High Pressure Hot Water (Steam) Cleaning ...................................................................12<br />
4.2.6 Emulsion Cleaning ..........................................................................................................12<br />
4.2.7 Rinsing.............................................................................................................................14<br />
4.2.8 Drying ..............................................................................................................................14<br />
4.2.9 Removal of Cleaning Agent.............................................................................................15<br />
5 Cleaning materials .........................................................................................................................15<br />
5.1 Mechanical Cleaning Materials...............................................................................................15<br />
5.1.1 Blast Cleaning .................................................................................................................15<br />
5.1.2 Wire Brushes...................................................................................................................16<br />
5.2 Chemical Materials .................................................................................................................16<br />
5.2.1 Alkaline Chemicals ..........................................................................................................16<br />
5.2.2 Acid Chemicals................................................................................................................16<br />
5.2.3 Solvents...........................................................................................................................17<br />
5.2.4 Water Based Detergents .................................................................................................18<br />
5.2.5 Emulsion Cleaners ..........................................................................................................18<br />
5.3 Cleaning Cloths ......................................................................................................................19<br />
5.4 Desiccating Materials .............................................................................................................19<br />
5.5 Drying/Purging Gas ................................................................................................................19<br />
Table 1: Industrial solvents 1 ..................................................................................................................20<br />
Table 2: Alkaline chemical cleaning materials (Also applicable to Alkaline Detergents)......................21<br />
Table 3: Acid chemical cleaning materials............................................................................................22<br />
Table 4: Common components in alkaline detergents and their main function ....................................23<br />
6 Inspection methods and acceptance criteria .................................................................................24<br />
6.1 Introduction .............................................................................................................................24<br />
6.2 Inspection Methods.................................................................................................................24<br />
6.2.1 Direct Visual Inspection with White Light ........................................................................24<br />
6.2.2 Direct Visual Inspection with UN. Light (Black Light) ......................................................25<br />
6.2.3 Wipe Test ........................................................................................................................25<br />
6.2.4 Solvent Extraction ...........................................................................................................25<br />
6.2.5 Water Break Test.............................................................................................................26<br />
6.2.6 Spectrometric, Chromatographic and other Special Methods ........................................26<br />
6.3 Detection Limits ......................................................................................................................27
<strong>AIGA</strong> 012/04<br />
6.4 Acceptance Criteria ................................................................................................................27<br />
6.4.1 Odour Test.......................................................................................................................28<br />
6.5 Inspection records ..................................................................................................................28<br />
7 Labelling for oxygen service ..........................................................................................................28<br />
8 Conservation of cleanliness...........................................................................................................28<br />
8.1 Protection Methods.................................................................................................................29<br />
8.1.1 Small Equipment .............................................................................................................29<br />
8.1.2 Large Equipment .............................................................................................................29<br />
8.2 Pressure Testing.....................................................................................................................29<br />
8.3 Notes ......................................................................................................................................29<br />
9 Design and manufacturing considerations for cleanliness ............................................................30<br />
9.1 Quality Assurance for Cleanliness when Buying Equipment or Components........................30<br />
Appendix A: Effect of CFC and VOC on the environment ....................................................................31<br />
Appendix B: Cleaning equipment working with aqueous agents and solvents.....................................32<br />
1 Considerations in the Equipment Selection Process.....................................................................32<br />
Appendix C: Cleaning of carbon steel pipeline .....................................................................................43<br />
Appendix D: Detergent cleaning of pipes with high pressure cleaning equipment...............................46<br />
Appendix E: Cleaning of a tubular heat exchanger in an ultrasonic bath using an aqueous cleaning<br />
agent .....................................................................................................................................................49<br />
Appendix F: Cleaning of parts in an ultrasonic bath using an aqueous cleaning agent .......................50<br />
Appendix G: Cleaning of a vessel with aqueous agent and solvent.....................................................51<br />
Appendix H: Cleaning of a vessel with aqueous agent.........................................................................53<br />
Appendix I: Cleaning of a transportable vacuum insulated vessel .......................................................54<br />
Appendix J: Remedial cleaning on a construction site .........................................................................55
1 Introduction<br />
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Oxygen is not flammable in itself but supports combustion. Oxygen can react with most materials.<br />
The higher the oxygen content and/or pressure in a system:<br />
- the more vigorous the combustion up to explosive levels<br />
- the lower the ignition temperature, up to ignition of materials, that normally do not bum in<br />
atmospheric air<br />
- the higher the flame temperature and combustion velocity.<br />
Care must be taken in the selection of equipment and materials, which need to be oxygen compatible<br />
and free from contaminants. The main contaminants to be avoided and/or eliminated are hydrocarbon<br />
oils and greases, which are easily combustible and particulate matter, which can easy ignite or cause<br />
ignition.<br />
Recognition of oxygen's reactivity led to stringent requirements regarding cleanliness of equipment in<br />
oxygen service.<br />
The first edition of this document issued 1986 recommended procedures and agents to clean and<br />
maintain the cleanliness of surfaces in contact with oxygen, inspection methods and acceptance<br />
criteria as well as practical examples.<br />
Cleaning with solvents (as a main procedure at that time in the oxygen industry) was recommended in<br />
most examples.<br />
The increasingly stringent environment regulations of the last years, regulations including the phasing<br />
out of most chlorofluorocarbons (CFC), restrictions in the use and the banning of some volatile<br />
organic compounds (VOC) led to the necessity to develop alternatives.<br />
This document has been updated to take into account the evolution of the regulations on<br />
environment.<br />
2 Scope and purpose<br />
This document deals with the cleaning of equipment or parts to be used in contact with gaseous or<br />
liquid oxygen and nitrous oxide or oxidizing gases/mixtures with an oxygen index > 25% (see prEN<br />
720-2 or ISO 10156).<br />
Particularly, this document describes cleaning methods, lists cleaning agents, and presents inspection<br />
methods and ways for conservation of cleanliness.<br />
3 International Agreements/Regulations<br />
This section gives an overview of the evolution and current status of the agreements/regulations<br />
phasing out or restricting the use of certain substances for environmental reasons.<br />
3.1.1 Ozone Depleting Substances<br />
Recognition of the contribution of CFCs to the depletion of the ozone layer has prompted a phasing<br />
out of these chemicals.<br />
Since the end of the 70's some countries tried to reduce the emission of CFC by issuing laws, and<br />
after 1980 it was tried by conferences to come to international agreements.<br />
The Vienna Agreement from 1985 was the result of a conference, but no specific measures were<br />
agreed then in the 1987 Montreal Protocol the involved countries agreed on concrete targets in the<br />
reduction of some substances. At the meetings in London 1990 and Copenhagen 1992 the phase-out<br />
dates were advanced and new substances added.<br />
A summary of the European Union legislation on CFCs is as follows
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The phase-out schedule, use, trade, and emission control and reporting provisions for ozone<br />
depleting substances is given in EU Regulation No. 2000/2037 replacing EC No 3093/94on<br />
substances that deplete the ozone layer. . Use of CFC and HCFC solvents is prohibited in noncontained<br />
solvent uses including open-top systems without refrigerated zone. More detailed<br />
information can be found in EIGA Environmental Newsletter No.5.<br />
3.1.2 Volatile Organic Compounds<br />
VOCs are a major source of 'photochemical smog' and ground level ozone that have harmful effects<br />
on human health and the environment.<br />
The main EU legislation covering the use of these substances is EU Directive 1999/13 on the<br />
limitation of emissions of volatile organic compounds due to the use of organic solvents in certain<br />
processes and industrial installations. One of the processes mentioned is surface cleaning.<br />
Installations using solvents above the thresholds specified in the Directive must<br />
• Comply with emissions limit values or solvent reduction plan<br />
• Have a solvent management plan<br />
• Have a permit for their activities<br />
More stringent control measures are required for the most hazardous solvents (with Risk Phrases<br />
R45, 46,49,60,61, i.e. carcinogenic, mutagenic, toxic to reproduction).<br />
The Solvent Management Plan should assist the operator:<br />
- to minimize emissions into the environment<br />
- to verify the limit values of emissions<br />
- to identify solvents which should, be substituted.<br />
Information on the effects of CFC and VOC on the environment and reasons for their banning are<br />
given in Annex 1.<br />
4 Cleaning methods<br />
4.1 Procedure and Agent Qualification<br />
4.1.1 General<br />
This section provides information to be considered when selecting a cleaning procedure/agent for an<br />
oxygen system.<br />
Selection of the appropriate method of cleaning shall be determined by the final level of cleanliness<br />
required as set out in section 4.<br />
There are a number of factors to be considered in choosing the most appropriate cleaning process.<br />
- Technical aspects (process suitability/cleaning effect)<br />
- Environmental and safety aspects<br />
- Economical aspects (costs involved)<br />
The selection criteria can be described as defining the characteristics required in the current situation.<br />
Each solution represents a compromise with advantages and disadvantages.<br />
Before a decision is made about which cleaning method has to be used, the need for cleaning must<br />
be considered and established. It might be possible to reduce cleaning operations by making changes<br />
in the production process.
4.1.2 Selection Criteria<br />
The procedure/cleaning agent should ideally meet the following criteria:<br />
Technical:<br />
- good degreasing properties<br />
- easily removable<br />
- non corrosive<br />
- compatible with commonly used metallic and non-metallic materials<br />
- cleaning agent and its residue to be compatible with oxygen<br />
- non flammable or low flammability<br />
Environmental / Safety :<br />
- non toxic<br />
- non ozone depleting<br />
- environmentally safe<br />
- disposable<br />
Economical:<br />
- inexpensive and readily available on the market<br />
- alternative suppliers<br />
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The American Society for Testing Materials (ASTM) has published for this purpose a guideline G 127,<br />
"Standard Guide for the Selection of Cleaning Agents for Oxygen Systems"<br />
4.1.3 Additional Technical Criteria<br />
Other technical aspects to be considered are:<br />
Size of parts:<br />
- small parts (e.g. up to 500 mm)<br />
- big parts as compressor casings, heat exchangers, vaporisers<br />
Form of parts:<br />
- simple<br />
- complicated/dead ends, crevices<br />
- elongated (pipes)<br />
Surface to be cleaned:<br />
- inner<br />
- outer<br />
- roughness<br />
Location where cleaning is carried out:<br />
- in the workshop<br />
- on the installation site<br />
Period when cleaning is carried out:<br />
- during manufacture,<br />
- commissioning,<br />
- maintenance<br />
State of the equipment to be cleaned:<br />
- assembled<br />
- disassembled<br />
Cleaning frequency:<br />
- continuously
- frequently<br />
- occasionally<br />
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4.1.3.1 Methods to Compare the Efficiency of Cleaning Agents<br />
It is necessary to have standard methods in order to compare the ability of cleaning<br />
procedures/agents to remove oil and grease contaminants from metals.<br />
In principle this can be carried out by contaminating test coupons, cleaning them and evaluating the<br />
cleaning effect by an adequate inspection method.<br />
ASTM has also developed two standards which may be used for these purposes:<br />
- ASTM G 121 "Standard practice for preparation of contaminated test coupons for the evaluation<br />
of cleaning agents".<br />
- ASTM G 122 "Standard test method for evaluating the effectiveness of cleaning agents".<br />
4.1.4 Health, Safety and Environmental Aspects<br />
The ideal agent is non-toxic or at least has a low toxicity. The main factors to take into consideration<br />
are:<br />
- Inhalation effects<br />
- Skin effects<br />
- Eye effects<br />
There are four main issues concerning the environment:<br />
- Emission to water<br />
- Waste disposal<br />
- Emission to air<br />
- Energy.<br />
Energy and emission to water are the main questions for consideration for aqueous cleaning, whilst<br />
emission to the atmosphere is of greater relevance for solvent cleaning.<br />
For environmental aspects see also IGC Technical Note 515/95 "Guidelines for Environmental<br />
Management"<br />
4.1.4.1 Emission to Water<br />
Whichever process is used, contamination of water arises from improper waste disposal, inadequate<br />
effluent water treatment or in the case of solvents, accidental spillage caused by improper handling or<br />
storage.<br />
4.1.4.2 Waste Disposal<br />
Degreasing with solvents gives rise to a residue containing oils, fats and greases. The solvent content<br />
can easily be reduced by distillation either in house or by a licensed recycler, thus recovering useful<br />
quantities of solvent. The residue emerges as a highly concentrated final waste.<br />
This should be disposed of by a licensed contractor and procedures should meet local regulations.<br />
Support and guidance are also available from the solvent suppliers.<br />
Cleaning in an aqueous system generates two types of effluent:<br />
- The spent cleaning bath contains chemical products necessary for the cleaning process and is<br />
also contaminated with oils and greases. This residue must be treated in a wastewater treatment<br />
plant which also generates a sludge requiring further processing before disposal.<br />
- The rinsing effluent is less contaminated, although still containing dissolved salts. Some effluent<br />
may be recycled to an earlier cleaning stage. Any final effluent will require treatment before<br />
discharge.<br />
The regulations for the treatment of spent aqueous cleaning effluent vary considerably from one<br />
locality to another.
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4.1.4.3 Emission to Air<br />
The limit values of emissions to air due to organic solvents are given in national regulations. There is<br />
also the before mentioned EU Directive on the limitation of the emissions due to cleaning processes<br />
(section 1.2.2).<br />
4.1.4.4 Energy<br />
Because of the wide variety of articles and circumstances in which they need to be cleaned, the<br />
energy requirements of cleaning processes vary considerably.<br />
The total energy demand for cleaning includes:<br />
- The energy needed for the production of chemicals<br />
- The energy required for the cleaning process, including recycling and waste treatment.<br />
When a drying stage is required aqueous cleaning processes can be more energy intensive than<br />
those using solvents.<br />
4.1.5 Costs<br />
All companies need to operate in the most cost efficient manner. However, in choosing a suitable<br />
process, costs are only the prime concern after the demands of technical performance, quality of<br />
cleaning, quality and reliability of the cleaned components, operator safety, and environmental<br />
requirements have been met.<br />
Cost analysis should take into consideration all costs connected to the cleaning process including<br />
personnel, health survey, materials, machines and waste disposal.<br />
4.2 Typical Methods<br />
Typical methods for cleaning of components, vessels and pipe work systems used in oxygen service<br />
are summarised in the following section and include:<br />
- Mechanical cleaning<br />
- Chemical cleaning<br />
- Detergent cleaning<br />
- Hot water (steam) cleaning<br />
- Emulsion cleaning<br />
- Solvent cleaning<br />
Appendix B gives examples of cleaning equipment working with aqueous agents and solvents. In<br />
Annexes III - X are given examples of different cleaning procedures.<br />
4.2.1 Mechanical Cleaning<br />
This cleaning method is not used for accurately dimensioned components as the method can cause<br />
uneven material loss. It is usually a preparatory stage in the cleaning procedure, but some processes<br />
such as blast cleaning can be used as a cleaning process provided oils and greases if present are<br />
removed in the process. Critical contaminations which cannot be eliminated by blasting (e.g. markings<br />
carried out with some marking pens) shall be noted and removed by another process.<br />
Selection of the mechanical cleaning method will depend upon several factors, which shall be<br />
considered:<br />
- The extent of contamination.<br />
- The ability of the method to remove the contaminants.<br />
- Unit or component to be cleaned, its shape and the ability to remove all cleaning debris and<br />
cleaning materials.<br />
- The effect of the cleaning materials/procedure relative to the construction materials.<br />
- The surface finish required in/on the unit or component.
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As a final stage in the mechanical cleaning method it is essential that all cleaning materials and debris<br />
are removed by brushing, vacuuming or high velocity blow out using dry oil-free compressed air or<br />
nitrogen or a combination of these.<br />
Mechanical cleaning is not suitable for non-metallic materials.<br />
Mechanical cleaning can take the form of chipping, scraping, flailing, grinding, wire brushing or blast<br />
cleaning.<br />
- Mechanical tube cleaners may be used. These are flexible shaft driven rotating wheel assemblies<br />
that carry out a chipping action on mill scale, etc.<br />
- Wire brushes manufactured from non-ferrous wire are recommended. Carbon steel wire brushes<br />
shall not be used on aluminium or stainless steel surfaces. Any wire brushes previously used on<br />
carbon steel shall not be used on aluminium or stainless steel surfaces. Wire brushing can be<br />
utilised with alkaline solutions to enhance that cleaning method.<br />
- Blast cleaning using abrasive materials such as grit, shot, copper slag, aluminium oxide, glass<br />
bead, sand etc. The blast cleaning method can be carried out using dry oil-free compressed air,<br />
nitrogen or high-pressure water as the carrying media.<br />
This method should not be used on aluminium alloys due to uneven metal loss and embedding of grit<br />
that can occur.<br />
It is recommended that blast-cleaning materials be used on a once through basis unless the material<br />
has been processed to remove any contaminants.<br />
Notes<br />
a) Specifications for materials are given in Section 3, Cleaning Materials.<br />
b) Surface finish alter mechanical cleaning is recommended to be as a minimum Standard N9,<br />
Rugotest No. 3 ISO 2632.<br />
Alternatives Sa 2 1/2 ISO 8501-1 or Swedish Standard SIS 055900.<br />
4.2.1.1 Health and Safety Precautions - Mechanical Cleaning<br />
Mechanical cleaning creates the formation of dust and other particles resulting from the breakdown of<br />
the materials used and also by the removal of surface material from the parts being cleaned. The<br />
particulate matter formed if breathed can be hazardous to health (e.g. quartz dust) and can also<br />
cause serious damage in contact with the eyes.<br />
1) Suitable full protective clothing, including breathing provision, head cover, gloves, apron, face<br />
shield and/or goggles must be worn by the operator and measures to extract excessive dust from<br />
the cleaning area must be employed when necessary.<br />
2) Hoses, nozzles, valves and accessories used shall be of a quality and condition suitable for the<br />
operation being undertaken.<br />
3) National regulations and manufacturers recommendations for ventilation and safe use of blast<br />
cleaning cubicles or rooms and blast cleaning equipment shall be observed.<br />
4.2.2 Chemical Cleaning<br />
Chemical cleaning is a process involving acid or solutions and is used to remove the following alkaline<br />
type of contaminants:<br />
- heavy or tenacious surface adherents<br />
- rust, scale and oxide films<br />
- brazing fluxes<br />
- small amounts of paint, grease, oil film and drawing compounds.<br />
The type of chemical cleaning material selected will depend, in most cases, on the equipment to be<br />
cleaned, the contaminants to be removed and the materials of construction. The manufacturer's
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specification for application of the cleaning agent and necessary safety precautions shall be strictly<br />
observed.<br />
Selection of the chemical cleaning method will depend upon several factors, which shall be<br />
considered:<br />
- Unit or component to be cleaned, its shape, size and ability to remove all residual cleaning<br />
materials.<br />
- Unit or component material and the possible effect of the cleaning material on the materials of<br />
manufacture.<br />
- Extent of material loss which car be permitted by exposure to acids.<br />
- Contaminants to be removed.<br />
- The surface finish required in/on the unit or component.<br />
Acid cleaning is not generally used for the removal of oils and grease and these contaminants, if<br />
present, should be removed by a solvent or by an alkaline solution prior to acid pickling.<br />
Chemical cleaning relates to the cleaning of components by the following alternatives:<br />
- Immersion in a tank containing the cleaning material. Addition of some kind of mechanical energy<br />
is normally required.<br />
- Spraying the equipment with the cleaning liquid.<br />
- Complete filling of the component with the cleaning material. This may be applied to large pieces<br />
of equipment.<br />
- Forced circulation of the cleaning material inside the component, in items such as tubular pieces<br />
of equipment.<br />
The cleaning materials are used as aqueous solutions of either acids or alkaline products. The<br />
solutions prepared will be in concentrations appropriate to the materials used in the construction of<br />
components and the surface condition required. Multiple cleaning operations are sometimes<br />
necessary to treat some metal surfaces, e.g. passivation to retard corrosion.<br />
After the completion of the chemical cleaning operation, by either acid or alkaline solution, all residual<br />
cleaning fluid must be completely drained from the component by flushing with clean oil-free water<br />
and purged.<br />
4.2.2.1 Alkaline Cleaning<br />
This cleaning method is normally carried out as a chemical cleaning process to remove oils and<br />
greases, with a caustic solution at elevated temperature, in the range of 38°C to 82°C (100°F to<br />
180°F), dependent upon solution concentration.<br />
Caustic solutions are made up from powders, crystals or concentrated solutions. All are water-soluble.<br />
Other chemicals with functions like water softening, corrosion inhibition and wetting are often added.<br />
The manufacturers specification for application of the cleaning agent shall be strictly observed.<br />
After cleaning, all components shall be thoroughly rinsed using oil-free water, preferably hot to aid<br />
drying, unless otherwise specified by the supplier of the chemical materials. This is particularly<br />
important for copper, copper alloys and stainless steel in order to avoid the risk of stress corrosion.<br />
4.2.2.2 Acid Cleaning<br />
This is normally carried out with an aqueous solution of acids at ambient temperature. Phosphoric<br />
acid cleaning solution car be used for metals, for the removal of oxides, light rust, light soils, fluxes<br />
and certain protective coatings.<br />
Hydrochloric acid solutions car be used for carbon and low alloy steels only. This solution will remove<br />
rust, scale, oxide coatings and will strip chromium, zinc and cadmium plating. It shall not be used on<br />
stainless steel and brass, which may as a result suffer stress corrosion.
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Hydrochloric and nitric acid solutions require the use of inhibitors as the solubility of metal oxides in<br />
the solutions results in corrosive attack on the base metal.<br />
Following pickling of ferrous surfaces using the above methods, passivation by use of phosphoric<br />
acid, sodium nitrite or phosphate treatment is necessary to prevent flash rusting.<br />
Chromic and nitric acid solutions car be used for cleaning aluminium, copper and their respective<br />
alloys. These solutions in themselves are not adequate cleaning agents, but are regarded as<br />
de-oxidisers for brightening metals dulled by alkaline solution cleaning. Nitric acid solution in<br />
combination with copper and copper alloys produces toxic fumes, and therefore good ventilation is<br />
essential.<br />
The manufacturer's recommendation regarding solution concentration, time and temperature shall be<br />
followed implicitly. Acid solutions should not be used unless their application and performance are<br />
known and have been discussed with the material supplier.<br />
After cleaning, all components shall be thoroughly rinsed, using flowing oil-free water, preferably hot<br />
to aid drying, unless otherwise specified by the supplier of the chemical materials. Special care should<br />
be given to carbon and low alloy steel components.<br />
4.2.2.3 Notes on Alkaline and Acid Cleaning<br />
a) Advice on aqueous acid and alkaline solutions will be found by reference to Section 3 (Cleaning<br />
Materials).<br />
b) Completion of the flushing operation can be assessed by monitoring the outlet water pH value or<br />
conductivity relative to the clean inlet water.<br />
c) Pumps, hoses, bulk tanks, piping and valves used for acid cleaning shall be acid resistant and<br />
compatible with the solution being used.<br />
d) Contaminated cleaning agents and residues must be stored and disposed of according to<br />
manufacturer's recommendations. Local and national regulations shall be observed.<br />
4.2.2.4 Health and Safety Precautions - Acid and Alkaline Cleaning<br />
1) Eye and skin contact with acid and alkaline chemicals should be avoided as bums or serious skin<br />
disorders can result. The breathing of fumes caused by the reaction of the chemicals with the<br />
metals being cleaned should also be minimised. Chemical cleaning agents shall only be used<br />
when their application, performance and health implications are fully understood and the<br />
manufacturers recommendations are complied with.<br />
2) Suitable protective clothing, gloves, apron or sometimes overall suits, face shield and goggles<br />
must be worn by the operator whilst carrying out chemical cleaning operations.<br />
3) Chemicals shall only be carried using suitable closed containers.<br />
4) When acid cleaning in enclosed vessels special precautions need to be taken due to the<br />
formation of inflammable hydrogen gas or toxic fumes resulting from contact of some acids with<br />
the metal surfaces.<br />
5) Acids shall always be slowly added to water when preparing aqueous solutions. Never use the<br />
reverse sequence.<br />
6) Acids and alkalis must never be disposed of directly into the drainage system. For further advice<br />
on environmental considerations and disposal methods refer to IGC Technical Note 515/95.<br />
4.2.3 Solvent Cleaning<br />
This cleaning or degreasing method has to a great extent been replaced by other methods because of<br />
safety and environmental reasons. In certain situations where other cleaning methods cannot be<br />
applied, solvent cleaning may be considered.<br />
The method is suitable for use with all metals; for use on aluminium refer to paragraph 2.2.3.5 item 7<br />
and for non-metallic to paragraph 2.2.3.4. Item b.<br />
Before starting a cleaning operation a reference sample of fresh clean solvent shall be retained. This<br />
sample will be used as a base reference. At intervals throughout the procedure, samples of used<br />
solvent shall be taken. These can be compared with the reference sample to determine the level of
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contamination and the cleaning procedure continued until the acceptance standard of cleanliness is<br />
reached.<br />
Methods of determining contamination can be by comparison of colour to reference sample,<br />
fluorescence under ultra violet light, by analysis, or by evaporation. (See Section 4 Inspection). Glass<br />
bottles are recommended to be used for containing check samples.<br />
Due to the potential hazard caused by solvents in contact with oxygen, after the completion of any<br />
method of solvent cleaning, all residual cleaning fluid must be totally removed from the components.<br />
An assessment of the component or system to be cleaned shall be made to ensure there are no pipe<br />
or other dead ends or pockets present from which it will be difficult to completely drain or blow out the<br />
solvent. If not, then this method shall not be used, or alternatively the system can be modified to<br />
accommodate this method. The component shall be thoroughly drained, purged, and dried with warm,<br />
dry, oil-free air or nitrogen. Small components may be air dried only, if appropriate. A method of,<br />
checking that residual solvents have been eliminated is by using a commercially available vapour<br />
detector/analyser on completion of the purge and drying process following cleaning.<br />
The unit used comprises an aspiration pump to measure the sample volume using disposable,<br />
calibrated, colorimetric detector tubes. This test can be supplemented by carrying out a sniff test when<br />
it is considered to be completely purged of solvent vapours.<br />
Solvent cleaning methods used are described in the following sub-sections. However, components of<br />
a simple shape and with all surfaces accessible may be cleaned by wiping with a solvent using a<br />
lint-free clean cloth and followed by drying.<br />
Potential users should determine whether the solvent has been declared acceptable by<br />
national authorities. Solvents shall only be used in stabilised form.<br />
4.2.3.1 Immersion in Solvent Method<br />
Cleaning of individual components can be effected by immersing the component in a tank of solvent,<br />
at ambient temperature, and applying a means of agitation.<br />
Disassembled parts can be cleaned by this method. The process can be improved by the use of an<br />
ultrasonic generator. Some methods utilising solvents are described in Appendix B Section 4.<br />
4.2.3.2 Forced Circulation Method<br />
Cleaning by forced circulation of a flow of the solvent liquid through the component can be carried out.<br />
This is done with the solvent at ambient temperature.<br />
The duration of cleaning by circulation shall be continued, using clean solvent, until the used solvent<br />
emerges from the component as clean as the solvent pumped in.<br />
This method is a highly specialised cleaning procedure and is applied principally to assemblies, which<br />
cannot be disassembled, large size components and prefabricated circuits, pipe works, etc. The use<br />
of this method is, however, limited by the ability of the solvent to reach contaminants present in a<br />
complex system and its subsequent complete removal.<br />
4.2.3.3 Vapour Phase Method<br />
Solvent vapour phase cleaning of components consists of the removal of contaminants by the action<br />
of continued condensation of solvent vapour on the component surfaces.<br />
The procedure requires that the equipment or component is colder than the solvent boiling point.<br />
A significant advantage of solvent vapour phase cleaning is that re-vaporised solvent is always clean<br />
and contaminants remain in the evaporator liquid section, which will require periodic cleaning out.<br />
A description of the method for one type of equipment is given in Appendix B.
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4.2.3.4 Notes on Solvent Cleaning<br />
a) Advice on suitable solvents will be found by reference to Section 3 (Cleaning Materials).<br />
b) Some plastic materials, including polyvinyl chloride (PVC) and poly-methylmetacrylate (PMMA)<br />
should not be used as containers as the plastics can be extracted by the solvent and be<br />
deposited on the component being cleaned. Similarly, rubber and neoprene are also affected.<br />
Therefore, products manufactured from these materials shall not be cleaned with chlorinated<br />
solvents.<br />
Polytetrafluoroethylene (PTFE) is satisfactory for use with chlorinated solvents and is the most<br />
frequently used material. Generally, non-metallic materials require confirmation of acceptability before<br />
use.<br />
4.2.3.5 Health and Safety Precautions - Solvent Cleaning<br />
Solvents are generally toxic and may act on the human body through inhalation, penetration of the<br />
skin and ingestion (see exposure limits for some solvents in Table 1). Some, such as<br />
dichloromethane, trichloroethylene and tetrachloroethylene are classified as suspected to be<br />
carcinogenic.<br />
Solvent cleaning agents shall only be used when their application, performance and health<br />
implications are fully understood and the manufacturer's recommendations are complied with.<br />
1) Vapours from some solvents are a powerful anaesthetic. Inhaled in small quantities it will cause<br />
drowsiness. In large quantities the vapour can cause unconsciousness and fatality. National<br />
regulations provide measures to control use of these products.<br />
Emission to the atmosphere has to be considered and kept to a minimum level and of course in<br />
accordance with legislation.<br />
Care must be taken that adequate ventilation is provided in areas utilised for solvent cleaning to<br />
prevent people breathing excessive amounts of solvent vapour or the products of decomposition.<br />
In solvent cleaning operations outdoors, it may be possible to locate the' working area to keep<br />
people up wind of solvent handling.<br />
Receptacles for the solvent shall not be left in working areas without lids or caps fitted, and shall<br />
be suitably labelled.<br />
To avoid exposure above permitted levels solvents shall not be removed from components by<br />
blowing dry in confined spaces.<br />
2) Some solvents may decompose to form very toxic gases, e.g. phosgene in the presence of heat<br />
sources (> 200°C) or ultra violet rays.<br />
Some mixtures are readily ignited with increased pressure and/or oxygen content.<br />
Most solvent vapours are capable of creating an explosive mixture at certain concentrations with<br />
air or oxygen.<br />
It is important to ensure that parts to be welded or heated shall be totally free of solvent.<br />
Smoking and the performance of any operations involving the use of flame, arcing or other source<br />
of heat higher than 200°C shall be prohibited on premises where vapours of halogenated solvents<br />
are present. Exposure of the solvent to daylight over a prolonged period may also cause<br />
decomposition of the material.<br />
Do not heat solvents above the allowable temperature. This temperature shall be checked with<br />
the solvent supplier or with other relevant information like the Material Safety 0Data Sheets.<br />
Do not use chlorinated solvents for cleaning closed tanks or other elements where it is not<br />
possible to ensure total removal of the solvent.<br />
3) Characteristics of solvents, toxicity, occupational exposure limits etc. will be found by reference to<br />
Section 3 (Cleaning Materials) and Table 1.
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4) Due to the harmful effects skin contact must be avoided by using nitrile gloves, apron and safety<br />
glasses with side shields or facemask. Note that polyvinyl chloride (PVC) gloves are only suitable<br />
for short periods of use.<br />
5) Solvents shall only be carried using suitable closed containers.<br />
6) Manufacturers of solvent cleaning plants and associated equipment, including ultrasonic methods,<br />
issue recommendations on safe operation procedures. Operators shall comply with the<br />
manufacturer's advice. Enclosed systems shall always be equipped with pressure relief devices<br />
and a pressure gauge. Heating of solvents shall always be by indirect methods.<br />
7) Aluminium and its alloys without the protective oxide film react vigorously with certain solvents to<br />
produce acid vapour, which is both toxic and corrosive. This particularly occurs on particles of<br />
aluminium such as swarf or grains from machining or cutting processes. When using solvents to<br />
clean aluminium; the following should be observed:<br />
- Use only clean solvent that contains the correct level of inhibitors for aluminium or light alloys.<br />
- Components should be placed gently into the degreasing tank to avoid rupturing the<br />
protective oxide film.<br />
- Newly machined aluminium and aluminium alloy components should be retained in the<br />
normal atmosphere in order to create an oxide film prior to being degreased.<br />
- Ensure that the material being cleaned is free from particles such as swarf or dust.<br />
- Solvents shall not be kept in contact with aluminium for extended periods. Alter cleaning<br />
remove solvents as quickly as possible.<br />
4.2.4 Detergent Cleaning<br />
This method relates to the cleaning of plant components, vessels, piping systems etc., either<br />
externally or internally.<br />
Detergent cleaning is done in water solutions containing chemicals with different functions like dirt<br />
solvency, dispersion, water softening, corrosion inhibition and wetting. It is normally performed in an<br />
alkaline environment, the higher pH value, and the better the degreasing efficiency.<br />
Detergents are supplied in solid or concentrated liquid form. They are prepared for use by mixing with<br />
hot water to form aqueous solutions. Prepared solutions can be pumped, re-circulated or jetted onto<br />
or through the component. They are well suited as cleaning agents in ultrasonic baths.<br />
The degreasing strength of detergents is as good as that of the solvents.<br />
Aqueous systems have few problems with worker safety compared to most other solvents. They are<br />
not flammable or explosive and toxicity is low for most formulations.<br />
The omission to water is the main environmental question to consider in aqueous cleaning.<br />
Dependent on local regulations, type of contaminants and detergent, concentrations, pH etc., the<br />
waste from water based detergent cleaning might be disposed of into the sewer for which a permit or<br />
consent may be required.<br />
4.2.4.1 Notes on Detergent Cleaning<br />
a) Before use, ensure that detergent chemicals used are suitable as some non-metallic materials are<br />
not compatible with the detergent chemicals or may absorb the fluid.<br />
b) Advice should be sought and followed from the detergent manufacturer regarding solution<br />
concentration, the materials it is suitable for, and safety precautions required<br />
c) For details with narrow cavities, the cleaning stage should be of the immersion type, where all<br />
parts of the contaminated details come in contact with the cleaning agent. Spray cleaning<br />
machines like a normal dishwasher is therefore an unsuitable alternative.<br />
d) Aqueous cleaners have higher surface tension compared to organic solvents and therefore<br />
difficulty in penetrating into threads and narrow cavities. To get a good contact between cleaner<br />
and contaminated details, some kind of mechanical energy should therefore be added. This<br />
mechanical energy might be provided by air agitation, jet flushing or ultrasonic. Rotation may be<br />
necessary to ensure elimination of air pockets.<br />
e) Increased temperature improves the cleaning. The cleaning bath should therefore be equipped<br />
with a heating device and temperature control.
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f) An aqueous cleaning system requires a subsequent rinsing step. It is important that all cleaning<br />
products, grease as well as cleaner residues, are removed. The rinsing step must be performed<br />
immediately alter the cleaning stage, before the cleaned details have dried. The higher rinsing<br />
temperature, the better. The final rinsing must be done with clean water.<br />
g) When water based cleaners with water rinsing are used, there is a risk for corrosion. Freezing of<br />
remaining water may also be a problem in certain installations.<br />
The system then needs to be carefully dried out. A purge of dry oil free air or nitrogen (min -40°C<br />
dew point) might be used. A final rinsing with alcohol (e.g. isopropyl alcohol) after water rinsing for<br />
improved water removal- might be used if the flammability risks can be controlled.<br />
Care should be taken when drying out the system, not to rely purely on exit gas dew point<br />
readings. Prior to commencing drying, drain points should be checked to ensure that all<br />
freestanding liquid has been removed. Blowing through with dry oil free air or nitrogen at ambient<br />
temperature normally takes a very long tune to achieve the necessary dryness.<br />
h) It is important that water-containing detergent is not directed to an oil/water separating system, as<br />
it will prevent such a system operating correctly.<br />
4.2.4.2 Health and Safety Precautions - Detergent Cleaning<br />
1) Operators carrying out detergent cleaning shall wear goggles or facemask and gloves.<br />
2) Skin contact with detergent chemicals should be avoided as serious skin disorder can result.<br />
3) Materials used for pumps, hoses, valves and accessories shall be compatible with the selected<br />
detergent to be used.<br />
4) The manufacturer's product information and material safety data sheets must be carefully studied.<br />
4.2.5 High Pressure Hot Water (Steam) Cleaning<br />
This method can be carried out using commercially available specialised equipment (one type<br />
described n Appendix B section 3.1) for complete external and internal cleaning of major plant parts<br />
and pipes with internal diameters down to approximately 10 mm. It removes oil and grease as well as<br />
welding and brazing residues and other contaminants. The addition of detergents can improve the<br />
performance of this cleaning method. (One typical application is described in Appendix D)<br />
The cleaning medium is heated potable water or water/steam which is jet sprayed onto the work<br />
pieces at a pressure of up to 180 bar. If a large flushing effect is required water only is used. The high<br />
temperature and the high pressure ensure that all contaminants are removed from the surface and<br />
washed away.<br />
This method is not recommended for use on electrical equipment due to possible ingress of moisture.<br />
Due to the jet being at high temperature and pressure care must be taken to ensure suitability of<br />
equipment for cleaning by this method.<br />
Cleaning with high-pressure water demands an ample water supply, and good wastewater facilities.<br />
Wastewater must be directed to the foul sewer and not discharged directly to surface water.<br />
4.2.5.1 Health and Safety Precautions - High Pressure Hot Water Cleaning<br />
1) Protective clothing, gloves, apron, eye and face protection are recommended to be worn by the<br />
operator whilst carrying out high pressure cleaning.<br />
2) Follow the equipment supplier’s instructions for the use and handling of the cleaning lances. Both<br />
hands shall always be on the handles and grips of the spray lance.<br />
3) It is strictly prohibited that high pressure cleaning is used for personal cleaning.<br />
4.2.6 Emulsion Cleaning<br />
Emulsion cleaning is a process for removing heavy contaminants like oil and grease from the surface<br />
of parts. Oxides cannot be removed.<br />
Emulsions are used for the same type of parts as water based detergent cleaners. The applied<br />
methods and used equipment is also similar to detergent cleaning.
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In an emulsion, a solvent is emulsified in water by surface-active agents. The cleaning 'is effected<br />
mainly by the solvent in the droplets whereupon the cleaner together with the cleaning products are<br />
removed by water rinsing. The cleaning efficiency can be increased by adding alkaline agents and<br />
surfactants (tensides). The cleaning action of the emulsion then combines the advantages of both<br />
detergent and solvent cleaning.<br />
In other emulsion systems, water free solvents with added emulsifiers are used. The cleaning has<br />
then to be considered as solvent cleaning. The emulsifying of the solvent and cleaning products takes<br />
place first when water is added in the subsequent rinsing stage.<br />
The concentration of dissolved contaminants in the cleaner can normally become considerably higher<br />
for emulsions compared to aqueous systems before the cleaning effect diminishes. The penetration<br />
into narrow hollows is better than for pure aqueous systems.<br />
The cleaning is normally performed at ambient temperature.<br />
The impact on the working environment from emulsion cleaners originates from vaporised solvent.<br />
This impact is however smaller compared to pure solvent systems because of the low solvent<br />
concentration and low solvent vapour pressure.<br />
4.2.6.1 Notes on Emulsion Cleaning<br />
a) Before use ensure that emulsion chemicals used are compatible with all metallic and organic<br />
materials.<br />
b) The cleaning must be followed by careful rinsing to prevent contamination from re-depositing on<br />
the surface. The surface must not be allowed to dry between the cleaning and rinsing phase.<br />
The rinsing is especially important when high boiling petroleum derived solvents are used in the<br />
emulsion. A thin film of high boiling hydrocarbons may otherwise remain on the details alter<br />
cleaning, which might be a safety risk in oxygen service.<br />
c) As with pure water based cleaning, the cleaned parts need to be dried alter rinsing. A purge of dry<br />
oil free air or nitrogen (min -40°C dew point) in might be used. After water rinsing, a final rinse<br />
with alcohol (e.g. isopropyl alcohol) may be used to improve water removal if flammability risks<br />
can be controlled.<br />
d) The circulation and cleaning of spent cleaning liquid is relatively complicated in emulsion systems.<br />
Emulsified oil can be removed by ultra filtration, chemical decomposition, micro filtration,<br />
adsorption or biological treatment, but a lot of the chemicals in the cleaning liquid are normally<br />
lost in these operations.<br />
The used contaminated cleaner must be disposed of as a waste in fine with local or National<br />
Regulations.<br />
See also Notes on Solvent Cleaning (section 2.2.3.4) and Notes on Detergent Cleaning (section<br />
2.2.4.1 ).<br />
4.2.6.2 Health and Safety Precautions - Emulsion Cleaning<br />
When using emulsions, the risks with the applied solvents and other chemical components must be<br />
carefully considered.<br />
1) Advice shall be sought and followed from We emulsion manufacturer regarding contents of<br />
chemicals, solution concentration, the materials suitable for and the safety precautions required.<br />
2) Materials used for pumps, hoses, valves and accessories shall be compatible with the selected<br />
emulsion to be used.<br />
3) Emulsions are considered non-flammable in bulk form but can be flammable in an aspirated or<br />
mist conditions. Proper equipment design is essential to minimise risk from flammable mists.<br />
Some formulations can auto-oxidise into an undesirable condition.<br />
4) The equipment including venting system must be explosion proof because of exposure to<br />
vaporised solvent.<br />
5) Inhalation is the primary safety concern, but the degreasing of the skin must also be considered.
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Operators carrying out emulsion cleaning shall wear facemask with appropriate filter or goggles<br />
depending on the composition of the emulsion and on the operation conditions.<br />
Skin contact with emulsion chemicals should be avoided as serious skin disorder can result.<br />
See also Safety Precautions for Solvent Cleaning (paragraph 2.2.3.5) and Safety Precautions for<br />
Detergent Cleaning (paragraph 2.2.4.2).<br />
4.2.7 Rinsing<br />
The purpose of rinsing is to remove remaining cleaning agents and emulsified contaminants.<br />
This operation is performed after acid, alkaline, detergent and emulsion cleaning.<br />
After the cleaning stage, the parts are immediately transferred to rinsing, which must be done before<br />
the parts have dried.<br />
The rinsing operation can take place in one or several stages by immersion, spraying or a<br />
combination of these methods.<br />
In immersion baths, some type of agitation is necessary. This might be accomplished by using an<br />
impeller, water jets, air injection or movement of the parts. Ultrasonic energy can also be used to<br />
improve the rinsing efficiency.<br />
Spray rinsing can be used for details with smooth surfaces without cavities where all parts can be hit<br />
by the rinsing liquid.<br />
High rinsing temperature improves the rinsing efficiency. Hot rinsing water will also heat up the<br />
cleaned parts, which saves time in the subsequent drying stage.<br />
Cleaning agents with high alkalinity are more difficult to rinse away than other cleaners. Raised<br />
temperature may then be required.<br />
The final rinsing must be done with clean water.<br />
The removal of liquid from the details after rinsing can be enhanced by blowing off with nitrogen or<br />
oil-free pressurised air.<br />
It is extremely important to perform the rinsing operation very carefully to ensure that all cleaning<br />
products, cleaner residue as well as contaminants, are completely removed. The supplier of the<br />
cleaner should be consulted when the rinsing conditions are decided.<br />
4.2.8 Drying<br />
Drying is applied to prevent corrosion and to speed up the total cleaning process in processes where<br />
water rinsing is used. This drying operation is often the most time consuming stage in the overall<br />
cleaning process. It may be performed in separate drying equipment or as an integrated stage in an<br />
automated cleaning apparatus.<br />
Drying is accomplished either with hot gas (convection) or radiation.<br />
In hot gas drying, the necessary energy for water vaporisation is transported to the goods by the hot<br />
gas itself.<br />
In drying by radiation, the walls of the drying chamber are heated up, emitting heat radiation, which in<br />
turn heats up the goods enough for water vaporisation.<br />
The gas temperature is often in the range of 70150°C for hot gas drying. In drying, using radiation, the<br />
parts are heated to a temperature of 150-200°C. This temperature has to be considered when drying<br />
polymeric materials.
Porous parts and parts with small or narrow cavities are difficult to dry.<br />
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The drying process can be hastened by immersing the wet parts into a solvent miscible with water<br />
(e.g. alcohol), which lowers the surface tension and causes the water droplets to flow out into a thin<br />
film.<br />
The humidified gas must be continuously vented from the drying chamber, as evaporation will cease<br />
when the gas is saturated with water vapour.<br />
4.2.9 Removal of Cleaning Agent<br />
Purging can be considered complete when the cleaning agent cannot be detected by appropriate<br />
methods in the gas venting from the vessel, piping or component being purged.<br />
If the odour of cleaning agent is detected in the vicinity of the effluent purge gas, the equipment<br />
requires additional purging.<br />
If the used cleaning agent is odourless, a leak detector specific for the cleaning agent has to be used.<br />
In the specific case of aqueous cleaning agent, the sole hazard is the deposit of the cleaning agent,<br />
which could be flammable.<br />
This situation cannot be possible if the choice of detergent insures that even the traces of solid<br />
residues of dry detergent are not flammable.<br />
5 Cleaning materials<br />
This section gives guidance on materials, which are suitable for use as cleaning agents, limits of<br />
application and precautions to be taken in using the materials. Most cleaning materials are not<br />
completely compatible with oxygen. Special care shall be given to the properties of the cleaning agent<br />
regarding flammability, toxicity, corrosion effect, and environmental impact.<br />
Tables 1 to 3 provide recommended materials. Materials used for pre-cleaning processes and final<br />
cleaning are included. Alternatives may only be used with reservation when the recommended<br />
materials are not obtainable and with particular precautions.<br />
Precautions must be taken when using cleaning materials according to the Material Safety Data<br />
Sheets (MSDS), the manufacturers recommendations, different local or national regulations and the<br />
rules of the supplier. Other general safety precautions to be taken are detailed in Section 2. Parts of<br />
equipment that are not compatible with the cleaning agent shall be removed or isolated.<br />
5.1 Mechanical Cleaning Materials<br />
The following materials are recommended for use for mechanical cleaning.<br />
5.1.1 Blast Cleaning<br />
Materials used for blast cleaning operations and their carrier shall be free from oil and grease.<br />
Blast cleaning of rough castings, forgings, plates, vessels, piping etc. can be carried out using the<br />
following materials:<br />
- Copper slag particles<br />
- Aluminium oxide<br />
- Glass beads in high pressure water or dry air<br />
- Sand<br />
Metallic shot (powder or grains of cast iron, iron, steel etc.) may be used. However, it is not<br />
recommended as in certain conditions it is capable of burning or initiating ignitions in oxygen. It shall<br />
therefore only be used if complete removal can be assured.
5.1.2 Wire Brushes<br />
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Wire brushes manufactured from stainless steel, copper, brass or bronze wire are recommended.<br />
Brushes shall be clean and in a good condition.<br />
5.2 Chemical Materials<br />
Chemical cleaning materials are included in the following paragraphs under the types of chemicals:<br />
- Alkaline Solutions<br />
- Acid Solutions<br />
- Solvents<br />
- Detergents<br />
- Emulsions<br />
Tables 1 to 4 provide examples of application of the chemicals included. The safety precautions are<br />
detailed together in paragraphs 2.2.2.4, 2.2.3.5, 2.2.4.2 and 2.2.6.2.<br />
5.2.1 Alkaline Chemicals<br />
Aqueous solutions of the following alkaline chemicals, often as mixtures, may be used as cleaning<br />
materials.<br />
Sodium hydroxide: NaOH (caustic soda).<br />
Sodium carbonate: NazC03 or sodium bicarbonate, NaHC03 (buffet solution)<br />
Sodium phosphate: Na3, Po4 (water softener, emulsifier and buffet).<br />
Sodium silicates: NaSi04 (emulsifiers and buffets).<br />
Refer to Table 2 for details of recommended alkaline materials for the metal involved and reason for<br />
cleaning. Other treatments required in addition to water rinse and drying are shown.<br />
5.2.2 Acid Chemicals<br />
Aqueous solutions of acids are used as chemical cleaning materials for the following applications:<br />
- chemical pickling<br />
- temporary corrosion protection (passivation)<br />
The acid chemicals used depend on the nature of the contaminant to be removed, the metal to be<br />
cleaned, and the application. Refer to Table 3 for details of recommended acid solutions for the<br />
material involved and the type of cleaning required. Other treatments required in addition to water<br />
rinsing and drying are shown.<br />
Acid cleaning of steel components is normally preceded by degreasing using solvent or alkaline<br />
treatments to remove oil or grease contaminants.<br />
Chemical pickling using aqueous solutions of acids is applied to vessels or pipe fabrications made of<br />
carbon or low alloy steels and removes rust, scale and certain protective coatings. The operation shall<br />
be completed by rinsing with a neutralising product or with running clean oil free water until the rinsing<br />
water outlet pH is neutral.<br />
The following acid solutions are used for this application.<br />
Nitric acid, HN03<br />
Hydrochloric acid, HCl<br />
Sulphuric acid, H2S04<br />
Chromic acid, H2Cr04<br />
Hydrofluoric acid, HF (stainless steel only)<br />
Phosphoric acid, H3P04
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Chemical passivation is a treatment used to provide temporary corrosion protection of carbon and low<br />
alloy steel surfaces, which have been pickled. Phosphoric acid (H3P04) or sodium nitrite solutions are<br />
used for this treatment. After treatment, the equipment shall be completely washed, drained and<br />
dried. Surfaces treated in this way have a uniform grey colour, occasionally with some highlights of a<br />
reddish brown colour due to deposits of salts of the passivation products. Any blackish deposits left<br />
on the surface which are slightly sticky to touch, are an indication that draining after passivation has<br />
been incomplete. Whitish surfaces with a tendency to be floury indicate incomplete drying.<br />
Acid solutions that attack the base metal or react with contained moisture may require the addition of<br />
inhibitors.<br />
There are commercially available products and solutions designed either for de-scaling or for<br />
anti-corrosive protection, or to fulfil both of these functions simultaneously. The exact compositions of<br />
these products are not always provided. They should not, therefore, be used unless compatibility tests<br />
have demonstrated the safety of the<br />
5.2.3 Solvents<br />
Some chlorinated solvents are still acceptable and established alternatives include hydro<br />
chlorofluorocarbons (HCFCs), aliphatic hydrocarbons and some specialised constant boiling blends.<br />
The use of HCFCs should only be regarded as a transition alternative due to the possibility of their<br />
phasing out in the future.<br />
Chlorinated solvents offer an advantage in that they tend to be usable in conventional degreasing<br />
equipment. A selection of solvents for cleaning oxygen service equipment is listed in Table 1.<br />
Pertinent data that is available on these products is also included.<br />
Although the solvents listed are low in their ozone depleting potential, they are volatile organic<br />
compounds and will, in some cases, also have a global warming potential. This should be taken into<br />
account when considering any investment in cleaning equipment.<br />
In addition to the cleaning ability of the solvent, material' compatibility, toxicity and environmental<br />
issues in the application, and waste disposal aspects must ail be considered when choosing the most<br />
suitable solvent for a given cleaning application. On completion of cleaning it is essential that all<br />
traces of solvent remaining are removed. If necessary, this should be confirmed with appropriate<br />
detection equipment (e.g. halogen leak detector or detector tube for chlorinated solvents). When the<br />
favoured method of cleaning is to use a solvent, its choice will represent a compromise combination of<br />
relevant properties. Solvents used shall be of a stabilised grade of proven suitability.<br />
It is important to ensure that the solvent is compatible with the materials used in the construction of<br />
parts being cleaned. Un-stabilised solvents can cause metal corrosion. The presence of moisture<br />
accelerates the corrosive effects of trichlorethylene and it is therefore essential that care is taken to<br />
maintain the quality of the solvents in use.<br />
Solvent degreasing must be carried out in a well-ventilated area and appropriate personal protective<br />
clothing should be used. The occupational exposure limits/threshold limit values shall be considered.<br />
Any changes of cleaning agent must be accompanied by a rigorous assessment of the risks to health<br />
of those involved in the changed process. Any necessary controls must be established and<br />
information provided to those involved with the changed solvent. This is required by legislation in most<br />
countries.<br />
Flammability is an important safety issue with hydrocarbons.<br />
Alcohol, oil spirits, some solvents and dry residues of aqueous detergents are flammable with oxygen.
18<br />
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These characteristics of flammability are well known and the use of flammable products for oxygen<br />
cleaning is strongly limited. However if this type of product is used, the procedure for rinsing, purging<br />
and checking has to be carefully qualified.<br />
It shall be ensured that after the complete procedure no residuals of flammable vapour or liquid<br />
remain in the equipment especially in complicated configurations, dead ends etc.<br />
The qualified procedure is specific for a given equipment.<br />
When non-flammable solvents are chosen, hydrocarbon-free grades should be used.<br />
The recycling of solvents and their ultimate safe disposal must conform to national legislative<br />
requirements. Accurate records should be maintained with a view to establishing a mass balance.<br />
Where disposal of spent solvent is required, it will normally be necessary to employ an approved<br />
professional waste disposal agent.<br />
National legislation will normally stipulate the storage and transport requirements. All solvent,<br />
recovered solvent and waste must be clearly labelled. Solvent must never be discharged directly into<br />
drains, sewers or natural watercourses. Checks should be carried out on the purity of solvent that is<br />
reused or has been recovered.<br />
5.2.4 Water Based Detergents<br />
Detergent cleaning is done in water solutions containing chemicals with different functions. It is<br />
normally performed in an alkaline environment, the higher pH value, the better the degreasing<br />
efficiency<br />
Common components in alkaline detergents and their main functions are shown in table 4.<br />
The most important detergent components are the surfactants. They decrease the surface tension of<br />
the water solution, penetrate the organic contaminants and make them disperse as small droplets into<br />
the water solution.<br />
Proprietary synthetic detergents are available for use to clean different polymers, metals and alloys. It<br />
is most important the manufacturer's recommendations are complied with and also the effect on any<br />
non-metallic materials which are present.<br />
5.2.5 Emulsion Cleaners<br />
Emulsion cleaner systems have three main components - water, an organic solvent and surfactants.<br />
They are used in two ways:<br />
- The solvent emulsified in water is applied in a manner similar to standard aqueous cleaners. The<br />
solvent is the main dirt dissolver and the surfactants work principally as emulsifiers.<br />
- Water-free solvents with added emulsifiers are applied in concentrated form and then rinsed with<br />
water. The emulsifying of the solvent and cleaning products takes place first when water is added<br />
in the subsequent rinsing stage.<br />
For safety and environmental reasons, solvents with high flash point and low vapour pressure are<br />
normally chosen. Examples of solvents are different high) oiling hydrocarbons, citrus based terpenes.<br />
(e.g. d-limonene) and pine based terpenes. Other examples are esters (e.g. lactate esters) and glycol<br />
ethers.<br />
Proprietary emulsion cleaners are available to clean different polymers, metals and alloys. It is most<br />
important the manufacturers recommendations are complied with and also the effect on any<br />
non-metallic materials which are present.
5.3 Cleaning Cloths<br />
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Goths used for wiping components or small areas of equipment surfaces shall be clean, lint-free and<br />
free from traces of oil or grease. Cotton, linen or paper re commonly used materials.<br />
5.4 Desiccating Materials<br />
Desiccating materials are sometimes placed in equipment after cleaning to prevent any corrosion, or<br />
other deterioration due to humidity of air that may be present during the period of shipment or storage.<br />
The following may be used:<br />
- alumina<br />
- silica gels<br />
- molecular sieve<br />
- regenerated clays<br />
Certain colour additives may be included in the products to give an indication of the moisture content<br />
5.5 Drying/Purging Gas<br />
The gas used shall be dry air or nitrogen and free from oil, grease and particulate matter. Air is<br />
considered suitable when its content of oil, grease and particulate matter is less than 1 mg/m3 and<br />
dry if its dew point value is equal or lower than -40°C at 1.013 bar. For continuous purging of<br />
equipment, using air, filtered atmospheric air compressed by a non-oil lubricated compressor is<br />
recommended.
Solvent<br />
(trival / common name)<br />
CHLORINATED SOLVENTS<br />
Dichloromethane<br />
(Methylene Chloride)<br />
Chemical<br />
formula<br />
Table 1: Industrial solvents 1<br />
Occupat.<br />
Exposure<br />
Limit 2 ppm<br />
Solvent<br />
power Kauri-<br />
butanol<br />
Index 3<br />
20<br />
Flammable.<br />
limits in %<br />
CH2Cl2 100 136 11.7-68 39.8<br />
(1.5)<br />
Trichloroethylene C2HCl3 100 130 7.5-95 86.9<br />
(2.7)<br />
Tetrachloroethylene<br />
(Perchloroethylene)<br />
C2Cl4 50 90 10-65 120.9<br />
(7.1)<br />
Boiling point (°C)<br />
(Re. evap. time) 5<br />
<strong>AIGA</strong> 012/04<br />
ODP 6<br />
HGWP 7<br />
POCP 8<br />
ODP zero<br />
HGWP<br />
nil<br />
POCP 0.9<br />
ODP zero<br />
HGWP<br />
nil<br />
HYDROCHLOR<strong>OF</strong>LUOROCARBONS (HCFCs) Also used in blends with other solvents<br />
2,2-Dichloro 1,1,1<br />
trifluorothane (HCFC<br />
123)<br />
1,1-Dichloro -1fluoro-ethane<br />
(HCFC 141b)<br />
3,3-Dichloro-1,1,1,2,2<br />
pentafluoropropane<br />
(HCFC 225 ca)<br />
1,3-Dichloro-1,1,2,2,3<br />
pentafluoropropane<br />
(HCFC 225 cb)<br />
POCP 7<br />
ODP zero<br />
HGWP<br />
nil<br />
POCP 0.5<br />
C2HCl2F3 none 2 ODP 0.02<br />
HGWP<br />
0.02<br />
C2H3Cl2 F 61 5.6-17.7 4 32 9 ODP 0.11<br />
HGWP<br />
0.1<br />
C3HCl2F5 34 51.1 ODP 0.025<br />
C3HCL2F5 30 56.1 ODP 0.033<br />
MISCELLANEOUS SOLVENTS<br />
Acetone C3H60 750 3.0-11 4 56.5<br />
Isopropanol C3H80 400 2.5-12 4 82.5<br />
Methyl ethyl ketone C4H80 200 1.8-11.5 4 79.6<br />
Natural oils 10<br />
Notes on Table I<br />
1. Potential users should determine whether the solvent has been declared acceptable by national<br />
authorities. Solvents shall only be used in stabilised form.<br />
2. Occupational exposure limits are those cited in the UK by the Health & Safety Executive in the<br />
1994 edition of their annual publication. The figures refer to a time weighted average for an 8-hour<br />
day. The terminology used varies in different countries, e.g. threshold limit values (TLV) in<br />
Belgium, France, Italy, USA, MAK/TRK in Germany and MAC in the Netherlands. The values<br />
used should always be those cited in the National regulations relating to the country in which<br />
operations are being conducted.<br />
3. The Kauri-butanol index (KB) is a measure of the relative solvent power of the chemical. It<br />
corresponds to the volume of solvent which when added to a solution of kauri gum in butanol<br />
causes commencement of cloudiness in the solution. The better the product as a solvent, the<br />
higher the KB value.<br />
4. The figures quoted are the lower and upper flammability limits expressed as a percentage by<br />
volume of the vapour in air.<br />
5. The relative time of evaporation is the ratio between the evaporation time of the liquid concerned<br />
and that of diethyl ether at a temperature of 20±2° C and a relative humidity of 55±5%.<br />
6. Ozone depleting potential (ODP) is expressed relative to CFC- 11 (Fluorotrichloro-methane)= 1.<br />
7. Halocarbon global warming potential (HGWP ) is expressed relative to CFC -11 =1.<br />
8. Photochemical ozone creation potential (POCP) is a relative measure of the ability of volatile<br />
organic compounds to enter into reactions that lead to poor air quality due to the formation of low<br />
altitude ozone. The base is taken as ethylene = 100.<br />
9. Not suitable for cold cleaning.<br />
10. e.g.: proprietary orange oils/mineral spirits. They are typically of high boiling point (200°C) and low<br />
volatility.
Table 2: Alkaline chemical cleaning materials<br />
(Also applicable to Alkaline Detergents)<br />
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METAL USED <strong>FOR</strong> <strong>CLEANING</strong> CHEMICALS OTHER TREATMENT<br />
Carbon, Low<br />
Alloys Steels<br />
and 9% Nickel<br />
Austenitic<br />
Stainless Steel<br />
Copper and<br />
Alloys<br />
Aluminium and<br />
Alloys<br />
Removal of heavy soil,<br />
grease and oil<br />
Removal of heavy soil,<br />
grease, light oils and<br />
cutting fluids<br />
Removal of greases,<br />
lubricating oils, drawing<br />
compounds, oxides,<br />
metallic particles or other<br />
contaminants<br />
Removal of brazing fluxes Hot water<br />
Removal of greases, oils<br />
and oxides<br />
Mixtures of Sodium<br />
hydroxide, carbonates,<br />
phosphates and silicates<br />
and synthetic wetting agents<br />
Mixtures of Sodium<br />
hydroxide, carbonates,<br />
phosphates and silicates<br />
and synthetic wetting agents<br />
Mixtures of Sodium<br />
hydroxide, polyphosphates,<br />
silicates, carbonates, wetting<br />
agents<br />
Etching: Mixed solution of<br />
sodium hydroxide and<br />
sodium phosphate<br />
Non Etching: Mixed solution<br />
of sodium carbonate, sodium<br />
silicate, sodium<br />
pyrophosphate and sodium<br />
metasilicate<br />
Solutions should not be<br />
allowed to dry on the<br />
component, they must be<br />
thoroughly rinsed away<br />
before passivation<br />
(See Note 3)<br />
Usually bright dipped in<br />
dichromate chromic acid<br />
solution (See Note 3)<br />
Dilute nitric acid dip to<br />
remove deposits remaining<br />
after alkali dipping.<br />
Note:<br />
1) The manufacturers specification for application of the cleaning agent shall be strictly observed.<br />
2) After cleaning using alkaline chemicals, all components shall be thoroughly rinsed, using flowing<br />
oil-free water, preferably hot to aid drying, unless otherwise specified by the supplier of the<br />
cleaning materials.<br />
3) There is a risk of stress corrosion attack unless the components have all chemical cleaning<br />
materials removed.
Table 3: Acid chemical cleaning materials<br />
22<br />
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METAL USED <strong>FOR</strong> <strong>CLEANING</strong> CHEMICALS OTHER TREATMENT<br />
Carbon and low<br />
alloy steels<br />
Removal of scale and<br />
oxide films (pickling)<br />
Inhibited hydrochloric acid or<br />
sulphuric acid and wetting<br />
agents<br />
Removal of light rust<br />
Citric acid or sulphuric and<br />
phosphoric acids<br />
Cast Iron Removal of oxides Chromic acid and sulphuric acid<br />
Austenitic<br />
Removal of oxides, Chromic acid and sulphuric acid<br />
tarnish and scale and and hydrofluoric acid, or nitric<br />
Stainless Steel metallic deposits / and hydrofluoric and<br />
contaminants phosphoric acids<br />
Copper and<br />
Alloys<br />
Aluminium and<br />
Alloys<br />
Note:<br />
Removal of scale and<br />
oxide (pickling)<br />
Removal of oxides<br />
(Etching Cleaning)<br />
Hydrochloric or sulphuric acid<br />
Chromic / sulphuric acid,<br />
Nitric / Hydrofluoric acid,<br />
Phosphoric / chromic acid<br />
Dilute alkali dip to<br />
neutralise acid followed<br />
by passivation<br />
treatment using sodium<br />
nitrite or phosphoric<br />
acid<br />
Light scrubbing action<br />
helpful<br />
Nitric acid solution used<br />
to brighten<br />
Sulphuric and nitric and<br />
hydrochloric acids are<br />
used to brighten<br />
Nitric / phosphoric acid<br />
for chemical<br />
brightening.<br />
1) The manufacturers speci8cation for application of the cleaning agent shall be strictly observed or<br />
the properties of the metals can be impaired (e.g. hydrogen embrittlement).<br />
Time/temperature/concentrations are very important.<br />
2) Alter cleaning using acid, all components, except carbon and low alloy steels, (see 3.2.2) shall be<br />
thoroughly rinsed, using flowing oil-free water, preferably hot to aid drying, to avoid corrosion risk,<br />
unless otherwise specified by the supplier of the cleaning materials. Some components require<br />
treatment using neutralising solutions after certain cleaning procedures
23<br />
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Table 4: Common components in alkaline detergents and their main function<br />
Main function Examples of common components<br />
Dirt Dissolvers<br />
PH Raising Agents<br />
Dispersers<br />
Softeners<br />
Corrosion inhibitors<br />
Wetting Agents<br />
Sodium Hydroxide<br />
Potassium Hydroxide<br />
Sodium Carbonate<br />
Sodium Silicate<br />
Surfactants (Tensides)<br />
Sodium Silicate<br />
Polyphosphates<br />
Polyphosphates<br />
Borates<br />
Glyconates<br />
Sodium Silicate<br />
Borates<br />
Amines<br />
Polyphosphates<br />
Glyconates<br />
Surfactants (Tensides)
6 Inspection methods and acceptance criteria<br />
6.1 Introduction<br />
24<br />
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It is essential that equipment supplied for use in oxygen service comply with the users specified<br />
cleanliness requirements. Agreement on the manufacturer's detailed quality control procedures and<br />
standards is required between the manufacturer and the user.<br />
Inspection by the user at the manufacturer's location is desirable. Initial and periodical auditing of the<br />
cleaning method and cleanliness control provisions of the manufacturers' workshops or site<br />
installations, cleaning and quality control provisions and its use, is necessary.<br />
6.2 Inspection Methods<br />
Various methods exist for determining the cleanliness of the cleaned parts. It is necessary that the<br />
method selected complements the cleaning method used and shows whether the acceptance criteria<br />
are achieved.<br />
This section covers the most practical and effective methods available. Qualified inspectors with the<br />
necessary training and relevant industrial experience are needed for this activity.<br />
Parts that are inaccessible for inspection after assembly may require to be disassembled or inspected<br />
prior to assembly.<br />
If an inspection reveals the presence of non-acceptable contamination, with oil or grease, residues of<br />
cleaning agent, or particles, the item of equipment must be partially or even completely re-cleaned.<br />
Persistent rejection requires a re-evaluation of the cleaning methods used and of the quality control<br />
provisions.<br />
The usual inspection methods are:<br />
- Direct Visual Inspection with White Light<br />
- Direct Visual Inspection with Ultra Violet (U.V) Light<br />
- Wipe Test<br />
- Solvent Extraction<br />
- Water Break Test<br />
- Chromatographic and Spectrometric Methods and other Special Methods.<br />
The method(s) selected depends on the required cleanliness.<br />
6.2.1 Direct Visual Inspection with White Light<br />
This is the most simple inspection method used to detect the presence of contaminants on equipment<br />
with accessible surfaces. This method will detect without magnification small particulate matter, dust,<br />
oil, grease and moisture in amounts, which could be tool high. It shall be used in conjunction with<br />
other methods.<br />
It is important to have a sufficiently bright level of artificial or natural daylight.<br />
Acceptance criteria:<br />
Visual inspection of the surfaces under bright light shall show no evidence of:<br />
- organic material such as oil, grease, paint, etc.<br />
- cleaning agents including detergents<br />
- rust and loose scale, weld spatters, particles dust, fibres or Other foreign matter<br />
- flux residues from welding, brazing or soldering<br />
- moisture
6.2.2 Direct Visual Inspection with UN. Light (Black Light)<br />
25<br />
<strong>AIGA</strong> 012/04<br />
An UV-light with a wavelength of about 0,37 um is used in dark or near darkness at a distance of<br />
about 10 to 20 cm from the surface or piece being examined. Many common but not all hydrocarbons<br />
or organic oils fluoresce under UV-light. The method might indicate fluorescent areas to be further<br />
inspected by other tests such as wipe or solvent test.<br />
The intensity of the fluorescent reflection from various oils is very different. For some vegetable and<br />
chemical oils it is zero. Therefore it is important not to rely solely on the result of this test in evaluating<br />
the cleanliness of equipment cleaned for oxygen service.<br />
Note that excessive exposure to direct or reflected ultraviolet light can cause eye and skin damage<br />
and therefore care must be taken when it is being used and lamp manufacturers instructions shall be<br />
complied with.<br />
Acceptance criteria:<br />
This qualitative method can better be used, if the contaminating oil and its reflecting capacity are<br />
known. The method should be used in conjunction with a quantitative test. A low specified amount of<br />
small particles can be detected by the U.V -light-test.<br />
6.2.3 Wipe Test<br />
This test is useful when white light inspection and/or UV light inspection has been inconclusive or not<br />
possible.<br />
The surface is rubbed lightly with white filter paper or with clean lint-free cotton or linen cloth. This<br />
paper or cloth is examined under white light and/or U.V light to find any contaminating traces. Several<br />
areas of the parts surfaces shall be tested. Since it is not acceptable to leave cloth or paper particles<br />
on the equipment, this method is not suitable for rough surfaces.<br />
For example: A contamination of 1000 mg/m2 Oil uniformly distributed would have a thickness of<br />
approx. 1 µm.<br />
Acceptance criteria:<br />
A light oxide discolouration or dust is in some cases acceptable.<br />
Any stain from the presence of oil or grease is unacceptable.<br />
6.2.4 Solvent Extraction<br />
Solvent extraction is one of the methods giving quantitative figures regarding the amount of soluble<br />
contaminants. The method is used especially for inaccessible surfaces or as verification of a cleaning<br />
process or of other qualitative methods.<br />
For most small components it may be easier and more economical to disassemble for inspection or to<br />
inspect before assembly. It should be taken into account that this method of inspection is limited by<br />
the ability to reach and dissolve the contaminants if present. Local contamination in pockets of<br />
complex equipment may be detected using this method of inspection by getting successive slight but<br />
constant indications of contamination. Considerable experience is necessary to assess the results of<br />
this method.<br />
The method is based on the comparison of used and unused solvent. The level of or freedom from<br />
contamination present during solvent cleaning can be closely followed by taking successive solvent<br />
samples during the entire cleaning process until inspection confirms that the acceptance standard is<br />
reached. Checking the amount of contaminants in a used sample is a good indication of the<br />
cleanliness level reached.
The amount of contaminants in a sample can be determined in three ways.<br />
- weight of residue (laboratory test)<br />
- volume of residue (laboratory test)<br />
- light transmission (laboratory test for qualitative figures)<br />
26<br />
<strong>AIGA</strong> 012/04<br />
This method is accurate in determining low amounts of oil or grease residues with small tolerances.<br />
6.2.4.1 Weight of Residue<br />
A known quantity (MS) of a representative sample of unfiltered used solvent is contained in a small<br />
weighed beaker and is evaporated to dryness being careful not to overheat the residue and the<br />
weight (m2) of the residue established. In the same manner the weight (in, ) of residue from a similar<br />
quantity of clean unused solvent is determined.<br />
The difference in weight between the two residues and the quantity of representative sample used is<br />
related to the total quantity (Mv) of solvent used and can be taken to compute the amount of residual<br />
contaminant removed per square metre (mc) of surface area (A) cleaned.<br />
m<br />
c<br />
=<br />
m2<br />
− m ) mv<br />
/ m<br />
A<br />
( 1<br />
s<br />
m1 = weight of residue (clean solvent)<br />
m2 = weight of residue (used solvent)<br />
ms = weight of representative sample (used solvent)<br />
mv = total weight of solvent used<br />
A = surface area of component cleaned<br />
Mc = weight of contamination present per area cleaned.<br />
6.2.4.2 Volume of Residue<br />
A measured quantity of a sample of the unfiltered used solvent can be placed in an Imhoff cone and<br />
evaporated to dryness. The volume of residue can be measured directly and used to compute the<br />
volume contaminant extracted per square metre of surface area cleaned. Greater sensitivity can be<br />
achieved by successive evaporation of quantities of the same extracted solvent batch in the same<br />
Imhoff cone.<br />
6.2.4.3 Light Transmission<br />
A sample of the unfiltered used solvent is compared a reference sample of unused solvent by<br />
comparing light transmission through the two samples simultaneously. The difference in colour or light<br />
absorption of the solvents is a qualitative indication of the amount of contaminants dissolved. The<br />
quantity of any contaminant in a sample can be estimated by analysis techniques e.g. making use of<br />
V or infrared light.<br />
6.2.5 Water Break Test<br />
Drinking or distilled water is sprayed on a surface as horizontal as possible. If the amounts of oil or<br />
grease are very small an unbroken layer of water stays for some seconds. If higher amounts of oil or<br />
grease are on the surface the water quickly contracts and forms small beads or droplets between<br />
water free areas.<br />
6.2.6 Spectrometric, Chromatographic and other Special Methods<br />
The measuring instruments used for these methods are very different. For their use special operating<br />
instructions are necessary. By some of them low amounts of oil or grease contamination can be<br />
detected and measured. In some cases the tolerances are low.<br />
Another method is the Total Organic Carbon Analysis-TOC". The technique is based on oxidation of<br />
the samples in furnace in flowing oxygen. The COZ-concentration gives an accurate quantitative
27<br />
<strong>AIGA</strong> 012/04<br />
value of the total surface carbon content and also semi quantitative information on the presence of<br />
hydrocarbons (the amount of carbon can be considered as being 0,8 - 0,9 of the total hydrocarbon<br />
weight).<br />
6.3 Detection Limits<br />
The results of measurements depend in a physical and optical way on the contaminating agent e.g.<br />
type of oil or grease. This is the reason for the wide range of the detection limits given in the table<br />
below. The quoted ranges are for information only.<br />
Test method<br />
Informative threshold of detection<br />
mg/m 2<br />
bright white light 500 - 1700<br />
UV light 40 - 1500<br />
wipe test 30 - 600<br />
water break test 30 - 60<br />
TOC, solvent extraction < 10<br />
A combination of test methods results in a lower threshold of detection.<br />
6.4 Acceptance Criteria<br />
This section gives quantitative values for two pressure ranges.<br />
The pressure strongly influences the ability of the contaminant to ignite. Contaminants are foreign<br />
unwanted matter that tan have a negative effect on system operation life or reliability. They are<br />
mainly:<br />
a) oils greases detergents<br />
b) other foreign matter (solid particles, dust layers, liquids) being either<br />
- organic substances e.g. wood, paper, cloth, plastics, rubber, adhesives, fibres, paints or<br />
anticorrosive, solvents or<br />
- inorganic substances for instance metal chips, scale, weld splatter, welding rod remnants,<br />
rust particles, sand, water drops, or any other particles.<br />
Maximum allowable quantifies of foreign matters<br />
Pressure<br />
Range<br />
Bar gauge<br />
Oil, Grease,<br />
Detergents,<br />
coatings mg/m<br />
organic<br />
2<br />
Particles Moisture<br />
< 30 500 1 Single small chips or<br />
fibres can be tolerated 2<br />
No drops of water<br />
visible<br />
>30 200 1 Single very small chips<br />
or fibres can be<br />
tolerated 2<br />
No drops of water<br />
visible<br />
1) The values are given considering a uniform distribution of the contamination at a max temperature<br />
of 70 °C.<br />
The quoted figures should be considered as guidance only. Lower figures could be requested<br />
depending on the specific application (type and state of fluid, temperature, pressure, flow,<br />
velocity, product purity), or effects like migration.<br />
2) Clusters of fibres other particles and dust i.e. relative high local concentrations must not be<br />
visible.
6.4.1 Odour Test<br />
28<br />
<strong>AIGA</strong> 012/04<br />
If requested (e.g. for medical gases)- an odour test shall be performed. The odour can be determined<br />
by one of the following procedures:<br />
- During purging operations by sniffing a moderate flow of purge gas from the equipment being<br />
tested.<br />
- From equipment in service containing gaseous oxygen by sniffing a moderate flow of oxygen from<br />
the equipment being tested.<br />
- From equipment in service containing liquid oxygen by taking out a liquid sample for testing.<br />
Odour in the liquid oxygen sample is checked by evaporating to dryness a quantity of liquid in a<br />
loosely covered beaker with a fresh filter paper in the bottom. The cover is removed at the point of<br />
complete evaporation and the beaker is odour tested several times until, is has warmed to above<br />
the freezing point of condensed water on the outside.<br />
The result of the inspection shall confirm the absence of odour. In either of the above procedures do<br />
not place face directly in front of valve or beaker. Instead cup the band and bring some of the gas<br />
being vented towards the nose.<br />
6.5 Inspection records<br />
Records are made of inspections and acceptances for the cleaned equipment or assembly. The<br />
record will include:<br />
a) Identification of the item covered<br />
b) Cleanliness specifications<br />
c) Cleaning method employed<br />
d) Method of inspection<br />
e) Results of inspection<br />
f) Inspector's signature and date<br />
7 Labelling for oxygen service<br />
All equipment components and spare parts delivered single or bulk packed in accordance with this<br />
specification shall bear a label stating that the items have been<br />
- CLEANED <strong>FOR</strong> <strong>OXYGEN</strong> <strong>SERVICE</strong><br />
Additional information may be included as follows:<br />
- To be kept free from oil and grease particles and water.<br />
- Showing date of inspection and stamps of supplier or workshop.<br />
- Stating the designation of the equipment and its serial number (if applicable).<br />
- Warning of asphyxiation hazard if applicable indicating medium and pressure.<br />
The label must be visible and securely attached to -h item by an appropriate means and not invalidate<br />
oxygen clean condition. Avoid the use of adhesive labels directly on metals as the adhesive may<br />
cause corrosion and/or contamination.<br />
Any other information or notices required relative to shipping storage and cleanliness conservation to<br />
be included on labels is given in Section 6.<br />
8 Conservation of cleanliness<br />
The purpose of this section is to provide protection to conserve the cleanliness of equipment for<br />
oxygen vice during shipping and storage until installation prior to commissioning.
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Once a piece of equipment has been cleaned for oxygen service and certified as conforming to the<br />
cleanliness specifications (see Section 4) it shall be ably protected to prevent contamination.<br />
The protection provided will depend on a number of :ors such as the size and type of equipment,<br />
method of shipping, duration, and conditions of storage.<br />
The packaging material used shall be clean, strong, to be sealed, waterproofed and suitable for the<br />
purpose.<br />
8.1 Protection Methods<br />
8.1.1 Small Equipment<br />
Accessories or parts such as valves, gaskets, etc. shall be packaged individually, after cleaning in a<br />
clean polyethylene tube or, bag and sealed. Any openings on the parts shall be closed with<br />
degreased plastic or metal plugs. The interior of the sealed bag may be evacuated of atmospheric air<br />
or filled with oil free nitrogen.<br />
8.1.2 Large Equipment<br />
Openings on equipment shall preferably be sealed with degreased caps, plugs, or suitable blind<br />
flanges. The equipment may be purged of atmospheric air and filled with oil-free dry clean air or inert<br />
gas at a slightly positive pressure. A notice shall be attached stating that the equipment is under<br />
pressure and the pressurising medium used.<br />
8.2 Pressure Testing<br />
When any test is carried out on equipment after completion of the cleaning operation it is essential to<br />
conserve the oxygen clean conditions. The test medium shall be compatible with the equipment<br />
materials and free from contaminants.<br />
When a hydraulic test is carried out, oil free, clean water shall be used and after testing the equipment<br />
shall be dried, purged, and blown out. For pneumatic testing, oil- free, dry, clean air or nitrogen shall<br />
be used. The testing medium shall be removed before the equipment is put into service.<br />
8.3 Notes<br />
The packing must be carried out in the area(s) temporarily or permanently allocated to equipment for<br />
oxygen service.<br />
All equipment shall be labelled according to Section 5.<br />
The internals of equipment that are liable to rust, that cannot be purged with a dry inert gas, shall be<br />
protected by the insertion of fibre, perforated or porous sachets containing silica gel, activated<br />
alumina or similar moisture absorbing agent. The sachets shall be secured inside the equipment,<br />
preferably to a removable part such as a cap or blank flange.<br />
The equipment shall have a notice indicating that it contains moisture adsorbents, the number of<br />
sachets and their locations.<br />
The adsorbents may contain a colour-indicator that will change colour if saturated with moisture.<br />
Sachets shall, if possible, be connected in groups so that they can be removed together. Small loose<br />
sachets of desiccant shall not be used as they may inadvertently be left inside the equipment after<br />
installation. When removing the sachets, care shall be taken to ensure that they are intact and that all<br />
sachets are removed.
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Cleaned components shall be stored until installation in a suitable dedicated area free from<br />
contamination.<br />
The packing shall not be opened until the equipment is ready to be installed. Prior to installation, the<br />
cleanliness shall be checked again to ensure that the specified standard has been maintained, and<br />
that the equipment is suitable for oxygen service.<br />
9 Design and manufacturing considerations for cleanliness<br />
The ability to clean, and the method(s) to be used shall be considered in the design and manufacture<br />
of equipment and components for oxygen service.<br />
Where possible, components shall not have recesses that cannot be directly inspected for<br />
cleanliness.<br />
Preferably, components shall be cleaned prior to assembly, and cleanliness maintained throughout<br />
assembly and testing.<br />
Where this is not possible, trial assemblies shall be dismantled after cleaning and components<br />
examined for cleanliness.<br />
Only approved lubricants shall be used in the assembly of components.<br />
The root weld run on piping systems and small pressure vessels should utilise welding process 141<br />
[Tungsten inert gas arc welding (TIG welding)] to IS0857/IS04063, in order to ensure a smooth root<br />
weld profile on the surface exposed to oxygen.<br />
9.1 Quality Assurance for Cleanliness when Buying Equipment or Components<br />
Any supplier or sub-contractor supplying or cleaning equipment or components for oxygen service<br />
shall be evaluated.<br />
Quality records of acceptable suppliers and sub-contractors shall be maintained.<br />
Evaluation and records shall include, where appropriate:<br />
- Cleaning methods, equipment and fluids.<br />
- Method(s) used to evaluate cleanliness.<br />
- Training and experience of operatives.<br />
- Methods used to ensure cleanliness during testing.<br />
Records of inspections for cleanliness witnessed or subsequently carried out by the purchaser.<br />
Methods used to maintain cleanliness up to and during storage.
Appendix A: Effect of CFC and VOC on the environment<br />
1. Effect of CFC on the Environment / Reasons for their Banning<br />
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CFC due to their high vapour pressure vaporises very quickly and goes directly into the atmosphere.<br />
Since 1974 scientists have established that CFC deplete the ozone layer in the stratosphere.<br />
Only the discovery of the "ozone hole" over the Antarctic in the mid 1980's and subsequent research<br />
brought this problem to the attention of the public and politicians.<br />
Today, it is accepted that ozone depletion represents t global environmental problem.<br />
The ozone layer protects the biosphere against the strong U.V.-radiation of the sun. A reduction of the<br />
layer damages human beings, animals and plants skin cancer and genetic damage). Chlorine,<br />
produced as a result of CFC decomposition is mainly responsible for ozone depletion.<br />
The atoms of chlorine set free one of the three atoms of oxygen from the ozone molecule, which<br />
recombine n an oxygen molecule. Every chlorine atom reacts many times before entering into a stable<br />
combination.<br />
Another negative effect of CFC is the warming up of he atmosphere. Two figures: The "ozone<br />
depletion potential" (ODP) and the "halocarbon global warming potential" (HGWP) give an indication<br />
of he magnitude of the negative effects of different hydrocarbons.<br />
The ODP is defined as the ratio relative to the calculated depletion for CFC 11 taken as a reference.<br />
In a parallel manner HGWP is a relative figure taking the warming effect of CFC 11 as a reference.<br />
1GWP depends also on the atmospheric lifetime.<br />
2. Effects of VOC<br />
An organic compound means any compound containing at least carbon and hydrogen or in which<br />
hydrogen is replaced or completed by halogens, oxygen, sulphur or nitrogen.<br />
A VOC is an organic compound that is volatile under the particular conditions of use and which is<br />
used atone or in combination with other agents.<br />
Main representatives of the VOC in correction with cleaning processes are tetrachloroethylene,<br />
tetrachloromethane, trichloroethylene, and 1,1,1-trichloroethane.<br />
VOC evaporate and, as a result of photochemical reactions, cause atmosphere oxygen to be<br />
converted into tropospheric ozone under certain climatic conditions.<br />
For VOC a factor POCP (Photochemical Ozone Creating Potential) relative to that of ethylene is<br />
defined.<br />
Some VOC as 1, 1, 1- trichloroethane are also ozone depleting.<br />
Some values for the ODP, HGWP and POCP are listed on page 30.<br />
ODP values are taken from the EC-Directive, HGWP and the lifetimes from literature.<br />
Substance Formula ODP HGWP POCP Lifetime years<br />
CFC11<br />
CFC 113<br />
CCl3F<br />
CCl2-CClF2<br />
1.0<br />
0.8<br />
1.04<br />
1.4<br />
60<br />
90<br />
HCFC 141B CH3-CCl2F 0.11 0.1 7.8<br />
HFC 134a CH2F-CF3 0 0.025-0.291 15.5<br />
1,1,1-trichloroethane CH3-CCI3 0.1 0.022-0.026 6.3<br />
Trichloroethylene C2HCl3 0 0 7<br />
Tetrachloroethylene C2Cl4 0 0 0.5<br />
Dichloromethane CH2Cl2 0 0 0.9
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Appendix B: Cleaning equipment working with aqueous agents and solvents<br />
Table of Contents<br />
1 Considerations in the Equipment Selection Process<br />
2 Health, Safety and Environmental Aspects<br />
3 Cleaning Equipment for Aqueous Agents<br />
Working Principles and Applications.<br />
3.1 Mobile High Pressure Cleaning Equipment<br />
3.2 Wash Cabins for Manual Cleaning<br />
3.3 Manual Immersion Cleaning Equipment<br />
3.4 Automatic Immersion Cleaning Machines with Agitation<br />
3.5 Immersion Cleaning Equipment with Ultrasonic Energy<br />
3.6 Cabinet Jet/Spray Cleaning Machines<br />
4 Cleaning Equipment for Organic Cleaners<br />
Working Principles and Applications<br />
4.1 Vapour Degreasing Machines with Chlorinated Organic Solvents<br />
4.2 Immersion Cleaning Machines with Non-Chlorinated Organic Solvents<br />
4.3 Immersion Cleaning Machines with Emulsion Cleaners<br />
4.4 Wash Cabins for Manual Cleaning with Low Volatile Solvents<br />
5 Auxiliary Equipment<br />
5.1 Particle Removal<br />
5.2 Oil Separation<br />
5.3 Vapour Emission Control<br />
6 Figure Index<br />
1 Considerations in the Equipment Selection Process<br />
The selection of the cleaning process and equipment is based on:<br />
- cleaning agent to be used<br />
- surface properties of the parts to be cleaned<br />
- shape and geometry of the material<br />
- the types and amounts of contaminants<br />
The degree of automation, the size and capacity of the equipment is determined from<br />
- size of the material to be cleaned<br />
- required cleaning rate<br />
All equipment must, together with the used chemicals, fulfil as a minimum the legislation for health,<br />
safety and environment.<br />
The choice of equipment has to be based on the efficiency of cleaning versus cost.<br />
The efficiency is controlled by utilising typical samples, written procedures and requested criteria for<br />
cleanliness.<br />
2 Health, Safety and Environmental Aspects<br />
Aqueous cleaning agents may be highly alkaline and corrosive and special care has to be taken to<br />
avoid contact with eyes and skin, which might cause permanent damage. Inhalation is the primary<br />
health concern for cleaning equipment-using solvents, but the degreasing of the skin must also be<br />
considered.<br />
The water jet from a high pressure-cleaning machine can cut like a knife and can also throw loose<br />
particles around. Protective gloves, goggles and clothes must be used.
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The emission to water is the main environmental question for consideration in the use of machines for<br />
aqueous cleaning. The emission to the atmosphere is the main impact from solvents.<br />
The disposal of waste must follow local regulations. The disposal methods used for water-based<br />
processes will depend on type of contaminants, concentrations, pH etc. The residue from a solventbased<br />
process is obtained as a highly concentrated waste, which has to be disposed of according to<br />
regulations in force.<br />
All electrical equipment including that of the venting system must have the correct flame/explosion<br />
proof ratings as defined by national regulations when flammable solvents are used.<br />
For environmental aspects see also IGC document 113/03 ‘ Environmental Impacts of Transportation<br />
of Gases’.<br />
3 Washing Machines for Aqueous Agents<br />
3.1 Mobile High Pressure Cleaning Equipment<br />
Working principle:<br />
Fig. 1. High pressure cleaning equipment<br />
The main parts are a high-pressure water pump and a high-pressure hose with nozzles. The cleaning<br />
agent is applied at low pressure and the rinsing is then performed by high-pressure water with very<br />
high velocity. For more difficult contaminants, hot water is required. In some kind of equipment it is<br />
possible to inject the dissolved cleaner together with the high-pressure water.<br />
Applications:<br />
A high pressure cleaning apparatus is suitable for cleaning of big pieces of equipment with easily<br />
accessible surfaces like outer surfaces of pumps and compressors. Protect water sensitive parts of<br />
the equipment from high-pressure liquid that may penetrate into internal parts.<br />
This kind of equipment can also be used for internal cleaning of pipes. (See Appendix D "Detergent<br />
cleaning of pipes with high pressure cleaning -equipment").
3.2 Wash Cabins for Manual Cleaning<br />
Working principle:<br />
Fig. 2. Wash cabin for manual cleaning<br />
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The equipment can be open or covered by a lid, with or without venting. The pieces to be cleaned are<br />
placed on a grid or a perforated plate. The cleaner can be applied manually by brushing and/or by<br />
spraying at low pressure. The cleaner is then re-circulated via a particle filter. Some types of<br />
apparatus are equipped with automatic spraying with fixed nozzles or a rotating spraying arm. When<br />
the cleaner has become too contaminated for use, the tank is emptied and cleaned.<br />
The cleaning agent is normally used at ambient temperature. Alter rinsing with clean water, drying is<br />
done by dripping off followed by blowing with oil-free, dry, clean air or nitrogen.<br />
Applications:<br />
This type of equipment is suited mainly for intermittent cleaning of small details for instance in<br />
correction with repair and maintenance work.<br />
3.3 Manual Immersion Cleaning Equipment
Fig. 3. Immersion cleaning equipment with means for brushing and spraying.<br />
A) Cleaning vat<br />
B) Liquid level in “immersion mode”<br />
C) Perforated plate<br />
D) Liquid level in “spraying/brushing mode”<br />
E) Air inlet for agitation<br />
F) Cleaner reservoir<br />
G) Filter<br />
H) Pump<br />
I) Spraying/brushing device for manual cleaning<br />
K) Heating element<br />
Working principle:<br />
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The parts to be cleaned are placed on the perforated plate in the vat. By pumping cleaning liquid from<br />
the cleaner tank, the level in the vat rises so that all parts are immersed in the liquid. The liquid might<br />
be heated and agitated e.g. by air or nitrogen injection.<br />
After a while, the parts should be moved around in the vat for improved accessibility.<br />
When the contaminants have been dissolved, the liquid level is lowered below the perforated plate. If<br />
necessary, remaining contaminants can be removed by brushing and spraying.<br />
The rinsing is normally performed in a separate rinsing bath.<br />
The cleaning efficiency is strongly dependent on the shape and the quantity of the parts to be<br />
cleaned. It can be improved by replacing the air or nitrogen agitation by ultrasonic energy. It should be<br />
noted, however, that these two mechanical energy categories cannot be combined, as the air bubbles<br />
absorb the ultrasonic energy.<br />
The temperature is normally in the range 50-90°C. The appropriate cleaning conditions should be<br />
tested in co-operation with the supplier of the cleaner.<br />
Applications:<br />
Manual immersion cleaning is appropriate for small quantities of small size material. The dimensions<br />
of the cleaning vat set the upper size limit for the material to be cleaned. The lower limit is given by<br />
the mesh size of the basket. Details with dead space, narrow and deep cavities can successfully be<br />
cleaned in this type of equipment.<br />
3.4 Automatic Immersion Cleaning Machines with Agitation<br />
Working principle:<br />
The material to be cleaned is immersed into a bath containing heated cleaning agent. Agitation can<br />
be accomplished by thermal agitation, impellers, liquid nozzles or air injection. The agitation can also<br />
be carried out by rotating, lifting and sinking the material in the bath.<br />
In high capacity plants, the material is continuously transported e.g. in conveyors from the cleaning<br />
bath to one or several rinsing baths. A drying stage may also be integrated in the equipment. For<br />
small and medium capacities, all stages may be integrated in the same machine.<br />
Fig 4 shows a machine in which the agitation is accomplished by up-and-down movements of the<br />
parts in the cleaning liquid.
A) Heating element<br />
B) Lifting beam<br />
C) Up-and-down moving platform<br />
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Fig. 4. Automated cleaning equipment. Agitation by up-and-down movement of the material.<br />
Applications<br />
Automatic immersion cleaning in integrated machines is appropriate for small and medium size<br />
material. Provided efficient agitation can be arranged, details with narrow and deep cavities can<br />
successfully be cleaned in this type of equipment.<br />
3.5 Immersion Cleaning Equipment with Ultrasonic Energy<br />
A) Cleaning stage 1<br />
B) Cleaning stage 2<br />
C) Rinsing<br />
D) Ultrasonic transmitters<br />
The material flow is indicated by arrows in the upper part of the figure.<br />
Fig. 5. Ultrasonic cleaning with different liquids in one bath.<br />
Working principle:<br />
Immersion bath cleaning can be improved by adding ultrasonic energy. The equipment can be<br />
manual as well as automatic.
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An alternating current generates ultrasonic vibrations which give rise to cavitation bubbles in the<br />
liquid. When they implode, mechanical cleaning energy in the form of small jets is created.<br />
Cleaning of small parts can be performed in mesh baskets or in containers with holes, which are<br />
immersed into the main ultrasonic bath. Some of the ultrasonic energy is then lost however.<br />
Containers id baskets should not be made from soft material as they absorb much of the ultrasonic<br />
energy. The cleaning tune in ultrasonic baths is considerably porter compared to ordinary immersion<br />
cleaning.<br />
The liquid in the bath must be free from gas bubbles these absorb the ultrasonic energy. A pump<br />
design should be used which does not give rise to gas bubbles in the liquid. For the same reason, air<br />
agitation cannot be combined with ultrasonic energy. The rinsing and drying might be done in the<br />
same apparatus ( Fig 5 ), but is normally performed in separate stages.<br />
Applications:<br />
Ultrasonic cleaning is generally used for small and medium size parts. The method is not suitable for<br />
porous and soft parts because of their energy absorption properties.<br />
It is important that the ultrasonic waves reach all surfaces to be cleaned. The cleaning efficiency is<br />
strongly dependent on the shape, the quantity and the positioning in the bath of the parts to be<br />
cleaned.<br />
3.6 Cabinet Jet/Spray Cleaning Machines<br />
A) Mist rinsing nozzles<br />
B) Rotating material to be cleaned<br />
C) Heating element<br />
D) Pumps (one for cleaning and one for rinsing)<br />
E) Tubes spraying with nozzles<br />
F) Cleaning chamber<br />
G) Jet flushing nozzles<br />
H) Valve<br />
I) Filter<br />
J) Cleaner/ Rinsing reservoirs (located behind each other)<br />
K) Drainage valve<br />
Working principle:<br />
Fig. 6. Cabinet jet/spray cleaning machine.<br />
This new type of cabinet machine utilises a combination of immersion, flushing and spraying.<br />
Immersion is obtained by increasing the liquid level in the cleaning chamber. During this phase, a<br />
highly turbulent flow is created in the cleaning liquid by jet flushing nozzles. The details to be cleaned<br />
are placed in a basket or drum which can be rotated or rocked in the cleaning liquid simultaneously
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with flushing / spraying from the nozzles. The powerful agitation and mechanical impact gives a very<br />
good cleaning effect, which also may be utilised for decreasing the concentration of chemicals and<br />
the cleaning temperature.<br />
The cleaning stage is followed by rinsing with water from a separate tank in the same unit. It can also<br />
be equipped with facilities for drying, oil separation and chemical dosage.<br />
The whole cleaning sequence as well as the temperature are automatically controlled and can easily<br />
be changed to suit different cleaning situations.<br />
Short over all cleaning times can be obtained. Total time including rinsing and drying is typically 8 - 12<br />
minutes.<br />
Applications:<br />
Small and medium size details can successfully be cleaned in this type of apparatus. Typical<br />
examples are closely packed details with complicated shapes, cavities, crevices etc.<br />
4 Cleaning Equipment for Organic Cleaners<br />
4.1 Vapour Degreasing Equipment with Chlorinated Organic Solvents<br />
A) Cooling zone<br />
B) Vapour zone<br />
C) Liquid solvent<br />
D) Heating element<br />
E) Cooling tubes<br />
F) Vapour evacuation<br />
G) Lifting device<br />
Fig. 7. Traditional vapour degreasing equipment (In some countries only closed installations<br />
are allowed)<br />
Working principle:
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The chlorinated solvent is heated to its boiling point in the bottom of the vat with the vapour rising<br />
upwards. The parts to be cleaned are immersed in the vapour phase in the lower part of the vat (the<br />
vapour zone) where they are suspended during the cleaning process. The solvent condenses on the<br />
surface of the parts, dissolving oil and grease, which drain off together with the solvent, which<br />
accumulates in the bottom of the vat. The surplus of vapour is condensed on the cooled walls in the<br />
upper part of the vat (the cooling zone). Remaining vapour, if any, is evacuated through slots just<br />
below the upper edge of the vat.<br />
This self-distilling principle means that clean solvent condenses on the parts even if the solvent in the<br />
sump is heavily contaminated.<br />
During the cleaning procedure parts with cavities must be turned upside down for emptying of<br />
contaminated solvent.<br />
The cleaning stops when the temperature of -the parts reaches the boiling point of the solvent. If this<br />
happens before the parts are adequately cleaned, the parts have to be cooled down with cold solvent<br />
before the degreasing process can proceed.<br />
Vapour degreasing can be combined with ultra sonic immersion and spraying, usually in separate<br />
areas of the machine.<br />
Regular checks of the solvent in the sump according :o the solvent manufacturers recommendations<br />
is necessary to ensure that the condition of the solvent) being used is always suitable for safe and<br />
efficient use.<br />
Special precautions are necessary including the requirement of entry permits into a confined space,<br />
he use of suitable breathing apparatus and the wearing of protective clothing.<br />
Applications:<br />
Vapour degreasing can be applied to all kind of parts is the vapour can reach and condense on all<br />
surfaces. Problems may occur for small and thin details which ire quickly heated up to the boiling<br />
temperature.<br />
4.2 Immersion Cleaning Machines with Non-Chlorinated Volatile Organic Solvents<br />
A) Venting fan<br />
B) Lid<br />
C) Pump
D) Closed cleaner reservoir<br />
E) Cleaning bath<br />
F) Ultrasonic transmitters<br />
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Fig. 8. Closed immersion equipment for volatile solvents with supplementary ultrasonic.<br />
Working principle<br />
Equipment using volatile organic solvents are totally closed apparatus keeping the operator separated<br />
from contact with the solvent. The parts to be cleaned are immersed into the solvent, which is agitated<br />
by stirring or by ultrasonic energy. Spraying is also used.<br />
The parts are normally loaded into the empty vat, the lid of the cleaning machine closed, and the<br />
solvent pumped in from a separate closed solvent storage tank. After the cleaning cycle is completed,<br />
the solvent is pumped away from the vat. The solvent vapours are evacuated by the venting system<br />
before the lid or door is opened and the details are removed.<br />
Examples of solvent used are alcohol and acetone.<br />
Applications:<br />
This kind of equipment is mainly used for small parts.<br />
Organic solvents have normally low surface tension, which makes them suitable for cleaning of details<br />
with narrow cavities. Generally speaking, when compared with chlorinated solvents and alkaline<br />
aqueous agents, the non-chlorinated organic solvents are less universal with respect to dissolving<br />
different types of contaminants.<br />
4.3 Immersion Cleaning Machines with Emulsion Cleaners<br />
Working principle:<br />
For emulsions, the same type of apparatus can be used as for aqueous cleaners, provided that the<br />
risk with the applied solvent is considered.<br />
When water free solvents with added emulsifiers are used, the cleaning has to be considered as<br />
solvent cleaning. The equipment design and requirements are then the same as for pure solvents.<br />
Applications:<br />
Emulsion cleaners can be used for the same type of parts as for aqueous systems. The penetration<br />
into narrow cavities is better than for pure aqueous systems.<br />
It is important that the water rinsing that follows the cleaning stage removes all high boiling point<br />
residues that may remain on the parts.<br />
4.4 Wash Cabins for Manual Cleaning with Low Volatile Solvents<br />
Working principle<br />
The same type of wash cabins as for aqueous systems can be used with low volatile solvents,<br />
provided they are equipped with venting systems and the solvent properties are considered. Often<br />
these kind of cabins are designed for use with aqueous as well as low volatility solvents.
A) Venting<br />
B) Filter<br />
C) Pump<br />
Applications:<br />
Fig. 9. Wash cabin for manual cleaning.<br />
41<br />
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This type of equipment is suitable mainly for intermittent cleaning of small parts where all surfaces can<br />
be directly inspected. Examples are cleaning in connection with repair and maintenance work.<br />
Components cleaned by this method must be carefully checked for a residue from the cleaning<br />
solvent.<br />
5 Auxiliary Equipment<br />
Beside the equipment necessary for the cleaning process, there are also different kinds of equipment,<br />
which decrease the amount of waste and may save a lot of money.<br />
5.1 Particle Removal from Process Liquids<br />
The removal of particles from re-circulating process liquids is essential in order to minimise the wear<br />
on mechanical parts like pumps and valves and to avoid clogging the spray nozzles.<br />
The particles can be removed as sediment from the tanks or by different types of filters e.g. wire<br />
screen filters in the piping system.<br />
5.2 Oil Separation<br />
The lifetime and efficiency of cleaners and rinsing water depends on the maintenance of the original<br />
composition of these liquids. By re-circulating purified process liquids, considerable savings can be<br />
obtained in chemicals, water and waste dumping costs.<br />
The oil in the spent cleaner or rinsing water can exist Fig, free oil or as an emulsion.<br />
Free oil can be separated by means of gravity, by filtration or by adsorption. Examples of equipment<br />
used are oil skimmer, lamella separator, coalescence filter, oil adsorbing bag filter, and propylene<br />
filter.
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Emulsified oil can be removed by ultra filtration, chemical decomposition, micro filtration, and<br />
adsorption or biological treatment. Evaporators and vapour compression apparatus are also used.<br />
5.3 Vapour Emission Control<br />
The control of vapour emission from solvent based cleaning equipment is essential from an<br />
environmental as well as safety viewpoint.<br />
In carbon or molecular sieve adsorption equipment, he vapour in the vent air is trapped in adsorption<br />
beds. When the beds are saturated, they are regenerated by steam or hot gas.<br />
Cryogenic condensation can also be applied, atone or in combination with carbon filter. The solvent is<br />
condensed from the vent air in a heat exchanger cooled with liquid nitrogen.<br />
6 Figure Index<br />
The following figure sources have been utilised<br />
Fig. 1 Company catalogue. Alfred K5rcher GmbH & Co.<br />
Fig. 2 J. Skogsmo, C. Norrby, "Handbok i Industriell Rengoring", The Swedish Institute of Production<br />
Engineering Research (IVF), 1994.<br />
Fig. 3 Own sketch.<br />
Fig. 4 Company brochure. Langeds Mekaniska AB.<br />
Fig. 5 J. Skogsmo, C. Norrby,"Handbok i Industriell Rengoring", The Swedish Institute of Production<br />
Engineering Research (I VF), 1994. Company brochure. Viverk Fbrsâljnings AB.<br />
Fig. 7 J. Skogsmo, C. Norrby, "Handbok i Industriell Rengoring", The Swedish Institute of Production<br />
Engineering Research (IVF), 1994.<br />
Fig. 8 J. Skogsmo, C. Norrby, "Handbok i Industtiell Rengoring", The Swedish Institute of Production<br />
Engineering Research (IVF), 1994.<br />
Fig. 9 J. Skogsmo, C. Norrby, 'Handbok i Industriell Rengoring", The Swedish Institute of Production<br />
Engineering Research (IVF), 1994.
1 General<br />
Appendix C: Cleaning of carbon steel pipeline<br />
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This annex deals with the distribution network from the supply stations of oxygen plants to the<br />
distribution stations at customers works.<br />
It does not deal with other parts of a complete network such as piping in the oxygen plant, distribution<br />
piping in the workshop, or at the points of use.<br />
2 Specific Design Requirements<br />
Pipeline shall be designed such that it can if necessary be cleaned by a 'pigging' operation.<br />
Consideration must be given to minimum bend radii and changes involving reductions in pipe<br />
diameter.<br />
Low level points where liquids or debris can accumulate should be avoided.<br />
Where this is not possible low point drains should be provided to facilitate drainage and visual<br />
examination.<br />
Drain points should be permanently blanked after pressure testing and/or cleaning has been<br />
completed.<br />
3 Materials and Components<br />
1 Pipe material - Carbon Steel<br />
2 Pipe fittings - Carbon Steel<br />
3 Proprietary – Pig launcher and catcher.<br />
4 Alternative A<br />
Involving use of components pre-cleaned to oxygen clean standard.<br />
4.1 Initial Cleaning Method<br />
All pipe lengths and pipe fittings to be purchased with internal surfaces blast cleaned. (surface finish<br />
Sa 2 1/2 to ISO 9501-1).<br />
4.2 Initial Inspection<br />
Inspection by direct visual method as per Para. 4.2.1 and 4.2.2 is normally sufficient. Pipe lengths and<br />
pipe fittings to be sealed with caps and waterproof masking tape immediately after cleaning.<br />
Desiccant bags should be placed inside each pipe and fitting as per Para. 6 on pages 27 & 28.<br />
4.3 Fabrication<br />
Exercise care in order to maintain cleanliness throughout subsequent fabrication and testing.<br />
Welds should be inspected as work progresses and any weld repairs executed. Pipe ends must be<br />
sealed at all times except when fabrication is actually taking place. A gas purge should be maintained<br />
during welding and between fabricating operations.<br />
Nitrogen gas may be substituted for argon back purge between welding. Paper dams to limit use of<br />
argon back purge should not be used. Trenches must be adequately drained of water.<br />
Attach pig launcher and catcher to ends of pipeline.
4.4 Post Fabrication Cleaning<br />
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Gauging pig made from oxygen compatible materials should be blown through line using nitrogen gas<br />
or oil free air as the propellant.<br />
Any debris removed from line should be examined to ensure that it is not contaminated by substances<br />
which are incompatible with oxygen.<br />
4.5 Pressure Testing<br />
If permitted by responsible authority, this should be a pneumatic strength test.<br />
Adequate safety precautions should be taken when carrying out this test.<br />
This would normally include having completed 100% radiographic examinations of all circumferential<br />
welds.<br />
If it is not permissible to carry out a pneumatic strength test, clean oil free water to which a<br />
deoxygenating agent and passivation agent has been added, should be used for a hydraulic strength<br />
test.<br />
Repeat pigging operation to remove water.<br />
Open drain points to remove any remaining water.<br />
Purge pipeline with dry nitrogen or clean air (minimum dew point -40°C).<br />
4.6 Post Test and Cleanliness Inspection<br />
Check dew point of purge gas.<br />
Check internals of pipeline for oxygen cleanliness by visual examination of ends and through drain<br />
points.<br />
Re-institute nitrogen purge and maintain until pipeline is ready for commissioning.<br />
5 Remedial Action<br />
Should visual examination show contamination, remedial action should be as per Para. 6.5 of this<br />
annex.<br />
6 Alternative B<br />
Involving use of components that have had components chemically cleaned to remove mill scale etc.<br />
6.1 Initial Cleaning Method<br />
Chemical cleaning by alkaline and/or acid pickling following by rinsing with clean water and<br />
passivation. Additional mechanical cleaning may be required.<br />
6.2 Initial Inspection<br />
Visual inspection to ensure that internals are free from mill scale, heavy rust, paint, varnish and<br />
hydrocarbons etc.<br />
6.3 Fabrication<br />
After fabrication attach pig launcher and catcher to ends of pipeline. Complete post weld examination<br />
as required by Design Code.
6.4 Pressure Testing<br />
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Carry out hydraulic strength test using clean oil free water to which a de-oxygenating agent and<br />
passivation agent has been added.<br />
Pig lire to remove water using a pig made from oxygen compatible material; with nitrogen gas or oil<br />
free air as the propellant.<br />
Open drain points, drain remaining water then close.<br />
Pneumatic test line if required by code.<br />
6.5 Post Test Cleaning<br />
Pass through pipeline two pigs with an approved solvent (such as Methylene Chloride) trapped<br />
between them.<br />
Pigs should be of the abradable type of a material that is both oxygen and solvent compatible.<br />
Pigs to be propelled by nitrogen gas or oil free air.<br />
Examine solvent for presence of contaminants per Para. 4.2.4 on pages 24 and 25.<br />
If contamination is present, repeat test- with fresh solvent until cleanliness is judged to meet the<br />
acceptance criteria in accordance with Para. 4.2:4 and 4.4 on pages 24, 25 and 26.<br />
Remove pig launcher and catcher.<br />
Purge pipeline with dry nitrogen (minimum dew point -40 °C).<br />
6.6 Post Test and Cleanliness Inspection<br />
As Alternative A, Paragraph 4.6.<br />
7 Remedial Action<br />
Should after repeated pigging with fresh solvent, the solvent is still found to be contaminated, possible<br />
remedial action is chemical cleaning in situ using alkaline and/or acid solutions followed by<br />
passivation and flushing with water and then post test cleaning as Alternative B, Paragraph 6.5<br />
above.<br />
Another possible remedial solution is shot blasting in situ using proprietary equipment.<br />
8 Additional Information<br />
Further information on the design, installation, fabrication and testing of a Carbon Steel Pipeline can<br />
be found in the IGC Document 13/02 entitled ' Oxygen Pipeline Systems’.
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Appendix D: Detergent cleaning of pipes with high pressure cleaning<br />
equipment<br />
1 Parts to be Cleaned<br />
Bent and straight pipes.<br />
Welded, brazed and soldered manifolds.<br />
Minimum internal pipe diameter:<br />
� Around 13 mm (Depending on hose and nozzle diameter).<br />
Maximum internal pipe diameter:<br />
� Around 300 mm (Depending on nozzle design and pressure.)<br />
Maximum bending angle:<br />
� 90°<br />
Minimum bending radius<br />
� 100-150 mm (Depending on pipe diameter, hose flexibility etc.)<br />
Material<br />
� Stainless steel pipes/manifolds. Some with brass connections soldered to the pipes.<br />
Maximum pipe length<br />
� Up to 30 m. Depending on hose length, number of pipe bends, pipe diameter.<br />
2 Processing of the Parts before Detergent Cleaning<br />
Stainless steel pipes exposed to different kind of treatment like bending, soldering and welding<br />
followed by pickling and pressure testing with potable water.<br />
3 Cleaning Equipment<br />
A high pressure cleaning equipment with high pressure flexible hose and pipe cleaning nozzles. (See<br />
fig 1).<br />
The backward directed jets from the nozzle pull the hose into and through the pipe while flushing the<br />
internal surface.<br />
Hot potable water or apparatus equipped with water heating facilities may be required for heavy duty<br />
cleaning.<br />
4 Cleaning<br />
The cleaning agent is applied at low pressure and ambient temperature via the hose and the nozzle.<br />
In this sequence, the hose must be transported through the pipe manually.<br />
The cleaner foam must wet the whole internal surface.<br />
The cleaner foam is left 5-10 minutes inside the pipe for dirt dissolving action. During this time period,<br />
the pipe should be rotated/turned around 2-3 times to ensure good cleaner accessibility.<br />
5 Rinsing<br />
The internal surface of the pipe is rinsed by warm high pressure clean water from the pipe cleaning<br />
nozzle. The hose is slowly transported back and forth so that all internal surfaces are in contact with
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the high pressure jet. Rinsing is continued until the pH value of the used rinsing water is the same as<br />
that of the fresh incoming water. (pH value may be tested by litmus reactive paper).<br />
The hose is normally self-transported forward through the pipe, but in case of numerous bends, pipe<br />
restrictions and other obstacles, the hose may need some manual help for transportation.<br />
In some cases, the cleaning/rinsing procedure may be repeated from other pipe openings.<br />
6 Drying<br />
Prior to commencing drying, all free standing water must be emptied from the pipe. Special care must<br />
be taken where dead ends and other pockets exist.<br />
The drying is effected by blowing through hot nitrogen or clean oil free air. It is important to check that<br />
all parts are reached by the hot gas.<br />
7 Cleaning Agent<br />
Water based alkaline detergent. A foaming agent is preferred due to its ability to stick to vertical<br />
surfaces. Several proprietary cleaners are available on the market.<br />
Cleaning conditions like detergent concentration, rinsing water temperature etc. should be determined<br />
through tests and should comply with the detergent supplier's recommendations.<br />
Typical conditions are<br />
� Cleaner concentration 20-50 %<br />
� pH, diluted solution 12<br />
� Rinsing temperature 50 °C<br />
�<br />
8 Safety<br />
Protective clothing, gloves, apron, eye and face protection are recommended to be worn by the<br />
operator whilst carrying out high pressure cleaning.<br />
Skin contact with detergent chemicals should be avoided as serious skin disorder can result.<br />
The manufacturer's product information and material safety data sheets must be carefully studied and<br />
followed.<br />
9 Inspection Method - Direct visual inspection with White Light.<br />
Wipe test all pipe openings. A cloth fastened to a lick may be used for wipe test of deeper internal<br />
surfaces.<br />
10 Conservation of cleanliness<br />
All pipe ends are sealed with plastic plugs.<br />
11 Labelling<br />
Cleaned for oxygen service<br />
Keep free from oil and grease<br />
Inspection date/stamp
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Fig 1. High pressure cleaning equipment and two types of pipe cleaning nozzles.
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Appendix E: Cleaning of a tubular heat exchanger in an ultrasonic bath using<br />
an aqueous cleaning agent<br />
1 Material / Size<br />
Approx. 900 x 4300 mm<br />
Copper/nickel alloy<br />
The outer surface of the pipes and the jacket which are in contact with oxygen have to be cleaned.<br />
2 Cleaning Method<br />
Immersion in ultrasonic bath.<br />
Cleaning agent : 1 % aqueous solution - pH neutral<br />
US-bath: 10 m x 2 m x 1.5 m. 8 oscillators, stainless steel<br />
Duration: 4 - 5 h; during this time period, the exchanger should be. moved/turned several times<br />
with a crane.<br />
Temperature: 50 - 60°C<br />
3 Rinsing<br />
Immersion in a second stainless steel bath with deionised water, 1.5 h at 40 - 50°C. Exchanger<br />
moved/turned 2 times.<br />
4 Drying<br />
In a tent with clean air 4 - 5 h at 30 - 40°C<br />
5 Inspection Method<br />
Wipe test and visual inspection with UV light.<br />
6 Conservation of Cleanliness<br />
Packed in a clean polyethylene bag (thickness > 0.15 mm) and sealed<br />
7 Labelling<br />
The bag is provided in and outside with a label. "Cleaned for oxygen service. Keep free from oil and<br />
grease. Inspection date/stamp".
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Appendix F: Cleaning of parts in an ultrasonic bath using an aqueous cleaning<br />
agent<br />
1. Size of Parts<br />
Generally up to 500 mm, depending on the capacity/dimensions of the bath.<br />
2. Material of Parts<br />
Steel, copper alloys. Cleaning of outer/inner surfaces.<br />
3. Cleaning Method<br />
Immersion in ultrasonic bath with/without pre-cleaning.<br />
3.1 Cleaning Agent<br />
20 % agent in water concentrate pH = 10<br />
3.2 Pre-cleaning<br />
In bath with or without ultrasonic.<br />
Duration : 15 min.<br />
Temperature : approx 60°C.<br />
Solution circulated by pump or slight manual movement of the basket containing the parts.<br />
3.3 Cleaning<br />
In ultrasonic bath (same conditions as in pre-cleaning bath).<br />
If oil spots are visible on the solution surface, this solution has to be renewed as well as the solution in<br />
The pre-cleaning bath. Used solution has to be disposed.<br />
4. Rinsing<br />
Immersion in bath/spraying as an alternative; with at approx. 40 °C.<br />
5. Drying<br />
Purging with dry, oil free air or nitrogen.<br />
6. Inspection Method:<br />
Certificated spot checks by wipe test or water break test.<br />
7. Conservation of cleanliness<br />
Packed in clean plastic bag and sealed.<br />
8. Labelling<br />
With a label “Cleaned for oxygen service. Keep free from oil and grease. Inspection date/stamp”;
Appendix G: Cleaning of a vessel with aqueous agent and solvent<br />
1. Material /Size<br />
Stainless steel or aluminium alloy<br />
Dimensions up to ∅ 3000 x 4000 mm<br />
2. Pre-cleaning<br />
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Prior to welding, vessel shell and ends are pre-cleaned separately with an aqueous agent (phosphate<br />
free with low alkaline content) at a temperature of approximately 50°C, then flushed with<br />
demineralised water for approximately 60 minutes.<br />
3. Inspection before Welding<br />
A wipe test is carried out after the drying operation. If there is any indication of grease or oil, the<br />
pie-cleaning operation is to be repeated.<br />
4. Cleaning<br />
After final welding a tube is installed in order to carry out a complete jet spray cleaning using solvent<br />
141 b (see figure and chapter 3, table 1).<br />
5. Inspection after Cleaning<br />
Quantitative control by solvent extraction (weight of the residue after vaporisation)<br />
6. Conservation of Cleanliness<br />
At all stages of assembly, components are protected against contamination. After inspection the tank<br />
is sealed with degreased flanges and slightly pressurised with nitrogen.<br />
7. Labelling<br />
"CLEANED <strong>FOR</strong> <strong>OXYGEN</strong> <strong>SERVICE</strong><br />
Pressurised with N2 ………………….bar<br />
Keep free from oil and grease<br />
Inspection date/stamp"
A) Jet tube<br />
B) Injection<br />
C) Condensation<br />
D) Purification<br />
E) Control<br />
F) Disposal<br />
G) Solvent recycling<br />
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1 Material/Size<br />
Appendix H: Cleaning of a vessel with aqueous agent<br />
Stainless steel; volume of the vessel from 1000 to 40000 litres.<br />
2 Cleaning Method<br />
2.1 Mechanical Cleaning<br />
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Before final welding interior surfaces shall be mechanically cleaned (grinding, brushing, grit blasting).<br />
2.2 De-dusting<br />
Internal surfaces shall be swept and vacuumed.<br />
2.3 Degreasing<br />
After welding and hydrostatic testing, a jet spray cleaning operation is carried out using phosphate<br />
free detergent (50°C, duration 1 h) followed by flushing with clean water at 50-60°C.<br />
3 Rinsing<br />
Spraying with de-mineralised water.<br />
4 Drying<br />
Purging with dry, oil free, clean air or nitrogen.<br />
5 Inspection<br />
Direct visual inspection with White Light and Ultraviolet Light.<br />
6 Conservation of Cleanliness<br />
At ail stages of assembly, components are protected against contamination. After inspection the<br />
vessel is sealed with degreased caps and slightly pressurised with nitrogen.<br />
7 Labelling<br />
"CLEANED <strong>FOR</strong> <strong>OXYGEN</strong> <strong>SERVICE</strong>"<br />
Pressurised with N2 …………….. bar<br />
Keep free from oil and grease<br />
Inspection date/stamp"
1. Material / Size<br />
Appendix I: Cleaning of a transportable vacuum insulated vessel<br />
Inner vessel and outer jacket: Stainless steel.<br />
Volume: Up to 500 litres.<br />
2. Initial Cleaning Method<br />
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Shell and vessel ends are purchased pre-cleaned and packed to oxygen standard. Root weld should<br />
be by y TIG welding in order to ensure smooth root weld profile and avoid welding debris.<br />
3. Cleaning Method<br />
Before final welding and isolation of the inner vessel the surfaces are manually cleaned with acetone<br />
using a dry cloth.<br />
4. Pressure Test<br />
Carried out with nitrogen or oil free air. Testing is carried out in a special container or chamber<br />
capable of withstanding a potential explosion of the vessel.<br />
5. Inspection Method<br />
Wipe test and UV light inspection of parts before final welding.<br />
6. Conservation of Cleanliness<br />
At all stages parts are protected against contamination.<br />
Openings are closed with caps.<br />
7. Labelling<br />
"CLEANED <strong>FOR</strong> <strong>OXYGEN</strong> <strong>SERVICE</strong>"<br />
To be kept free from oil and grease<br />
Inspection date/stamp"
Appendix J: Remedial cleaning on a construction site<br />
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Facilities and equipment readily available for re-cleaning on or near a construction site are frequently<br />
limited.<br />
When deciding on the method that can be used to a carry out remedial cleaning, consideration shall<br />
be given to the design, construction, size and materials of construction.<br />
While reference should be made to the original cleaning method, it should be appreciated by all<br />
parties, that duplication of any given cleaning method at another location, is often difficult.<br />
The original equipment manufacturer may be consulted on the proposed re-cleaning method.<br />
Facilities that can usually be provided on site are:<br />
� Portable high pressure steam cleaning<br />
� Pickling baths<br />
� Solvent or detergent baths.<br />
Small localised cleaning can be carried out by wiping with Tint free cloth and a solvent.<br />
Care shall be taken that no hazardous residuals remain.<br />
Care must be taken that the values of oil, grease and other contaminants are below the given figures<br />
acc. to this document.<br />
The cleaning procedure and the test-results should be recorded.